Valve for reciprocating pump assembly

ABSTRACT

The valve member includes a valve body and a seal. The valve body defines a first frusto-conical surface and an outside annular cavity. The seal extends within the outside annular cavity and includes a first tapered and circumferentially-extending surface adapted to sealingly engage the tapered surface of the valve seat. In another aspect, the seal includes an annular bulbous protrusion from which the first tapered and circumferentially-extending surface angularly extends, the first tapered and circumferentially-extending surface extending between the annular bulbous protrusion and the first frusto-conical surface of the valve body. In another aspect, an offset distance is defined between the first frusto-conical surface of the valve body and at least a portion of the first tapered and circumferentially-extending surface of the seal, the offset distance extending in a direction that is perpendicular to at least the first frusto-conical surface of the valve body.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.15/200,913, filed Jul. 1, 2016, the entire disclosure of which is herebyincorporated herein by reference.

U.S. application Ser. No. 15/200,913 claims the benefit of the filingdate of, and priority to, U.S. Application No. 62/188,248, filed Jul. 2,2015, the entire disclosure of which is hereby incorporated herein byreference.

U.S. application Ser. No. 15/200,913 also claims the benefit of thefiling date of, and priority to, U.S. Application No. 62/300,343, filedFeb. 26, 2016, the entire disclosure of which is hereby incorporatedherein by reference.

U.S. application Ser. No. 15/200,913 is a continuation-in-part of U.S.application Ser. No. 29/556,055, filed Feb. 26, 2016, the entiredisclosure of which is hereby incorporated herein by reference.

TECHNICAL FIELD

This disclosure relates in general to pump assemblies and, inparticular, valves for reciprocating pump assemblies.

BACKGROUND OF THE DISCLOSURE

Reciprocating pump assemblies typically include fluid end blocks andinlet and outlet valves disposed therein. During operation, the inletand outlet valves typically experience high loads and frequencies. Insome cases, valve seats of the inlet and outlet valves, as well as thecorresponding valve members adapted to be engaged therewith, may besubjected to highly concentrated cyclic loads and thus may suffer wearand damage, and fatigue to failure. Therefore, what is needed is anapparatus or method that addresses one or more of the foregoing issues,and/or other issue(s).

SUMMARY

In a first aspect, there is provided a valve member for an inlet oroutlet valve of a reciprocating pump assembly. The valve member includesa valve body defining first and second frusto-conical surfaces; anoutside annular cavity formed in the valve body; and a seal extendingwithin the outside annular cavity, the seal defining a tapered andcircumferentially-extending surface adapted to sealingly engage atapered surface of a valve seat of the inlet or outlet valve; whereinthe second frusto-conical surface defined by the valve body extendsangularly between: the first frusto-conical surface defined by the valvebody; and the tapered and circumferentially-extending surface of theseal.

In an exemplary embodiment, the seal further includes an annular bulbousprotrusion from which the tapered and circumferentially-extendingsurface angularly extends, the extension ending at, or proximate, thesecond frusto-conical surface defined by the valve body.

In another exemplary embodiment, the valve body defines a top surface;wherein the seal further includes a channel formed in the exteriorthereof; and wherein the channel is positioned between the top surfaceof the valve body and the annular bulbous protrusion.

In yet another exemplary embodiment, the outside annular cavity definesfirst and second angularly-extending surfaces; and wherein the valvemember further includes: an annular groove formed in the valve body atthe intersection of the first and second angularly-extending surfaces;and an annular element disposed in the annular groove and engaging theseal.

In certain exemplary embodiments, the valve member includes a base fromwhich the valve body extends, wherein the first frusto-conical surfaceof the valve body extends angularly between the base and the secondfrusto-conical surface of the valve body; and a plurality ofcircumferentially-spaced legs extending from the base and away from thevalve body, wherein the legs are adapted to slidably engage anothersurface of the valve seat.

In an exemplary embodiment, the base is a disk-shaped base that definesa circumferentially-extending convex surface.

In another exemplary embodiment, the valve member defines a first axisadapted to be coaxial with a second axis of the valve seat; wherein thefirst frusto-conical surface of the valve body defines a first anglefrom the first axis; and wherein the second frusto-conical surface ofthe valve body defines a second angle from the second axis.

In yet another exemplary embodiment, the first angle is greater than thesecond angle.

In certain exemplary embodiments, the second angle is adapted to besubstantially equal to a taper angle defined by the tapered surface ofthe valve seat and measured from the second axis of the valve seat; andwherein the second angle is about 50 degrees.

In an exemplary embodiment, the valve body defines a first surface areaadapted to contact the tapered surface of the valve seat; wherein theseal defines a second surface area adapted to contact the taperedsurface of the valve seat; and wherein a ratio of the first surface areato the second surface ranges from about 0.9 to about 1.2.

In another exemplary embodiment, the ratio is about 1.

In another exemplary embodiment, an offset distance is defined betweenthe second frusto-conical surface defined by the valve body, and atleast a portion of the tapered and circumferentially-extending surfacedefined by the seal.

In yet another exemplary embodiment, the offset distance extends in adirection that is perpendicular to at least the second frusto-conicalsurface.

In certain exemplary embodiments, the offset distance ranges fromgreater than zero inches to about 0.1 inch.

In an exemplary embodiment, the second frusto-conical surface defined bythe valve body and at least a portion of the tapered andcircumferentially-extending surface defined by the seal are spaced in aparallel relation; wherein an offset distance is defined between theparallel spacing between the second frusto-conical surface defined bythe valve body, and the at least a portion of the tapered andcircumferentially-extending surface defined by the seal.

In another exemplary embodiment, the offset distance extends in adirection that is perpendicular to at least the second frusto-conicalsurface.

In yet another exemplary embodiment, the offset distance ranges fromgreater than zero inches to about 0.1 inch.

In certain exemplary embodiments, the valve member defines a first axisadapted to be coaxial with a second axis of the valve seat; wherein afirst angle, as measured from the first axis, is defined by the secondfrusto-conical surface defined by the valve body; wherein a secondangle, as measured from the first axis, is defined by at least a portionof the tapered and circumferentially-extending surface defined by theseal; wherein the first and second angles are substantially equal; andwherein each of the first and second angles is adapted to besubstantially equal to a taper angle defined by the tapered surface ofthe valve seat and measured from the second axis of the valve seat.

In an exemplary embodiment, the seal further defines another tapered andcircumferentially-extending surface, which angularly extends from thefirst-mentioned tapered and circumferentially-extending surface definedby the seal.

In another exemplary embodiment, the extension of the another taperedand circumferentially-extending surface of the seal ends at, orproximate, the second frusto-conical surface defined by the valve body.

In yet another exemplary embodiment, an annular contact portion of theseal is defined by the intersection between the first-mentioned and theanother tapered and circumferentially-extending surfaces of the seal,the annular contact portion including at least a portion of thefirst-mentioned tapered and circumferentially-extending surface of theseal.

In certain exemplary embodiments, the valve member defines a first axisadapted to be coaxial with a second axis of the valve seat; wherein afirst angle, as measured from the first axis, is defined by the secondfrusto-conical surface defined by the valve body; wherein a secondangle, as measured from the first axis, is defined by thefirst-mentioned tapered and circumferentially-extending surface definedby the seal; wherein a third angle, as measured from the first axis, isdefined by the another tapered and circumferentially-extending surfacedefined by the seal; wherein the first and second angles aresubstantially equal; and wherein the third angle is greater than each ofthe first and second angles.

In an exemplary embodiment, the valve member includes a rupture discassembly engaged with the valve body.

In another exemplary embodiment, the valve member defines a first axisadapted to be coaxial with a second axis of the valve seat; wherein acounterbore is formed in the valve body and is generally coaxial withthe first axis, the counterbore including an enlarged-diameter portionand a reduced-diameter portion, the reduced-diameter portion defining afluid passage; wherein the counterbore defines an internal shoulderextending radially between the enlarged-diameter and reduced-diameterportions; and wherein the rupture disc assembly includes a rupture discdisposed in the enlarged-diameter portion and engaging the internalshoulder; and an annular seal sealingly engaging at least the rupturedisc and the internal shoulder.

In yet another exemplary embodiment, the rupture disc includes anannular mounting portion disposed in the enlarged-diameter portion, anend of the annular mounting portion engaging the internal shoulder; adomed rupture portion about which the annular mounting portioncircumferentially extends; and an annular channel formed in the end ofthe annular mounting portion engaging the internal shoulder; wherein theannular seal extends within the annular channel and sealingly engages atleast the annular mounting portion and the internal shoulder.

In a second aspect, there is provided a valve member for an inlet oroutlet valve of a reciprocating pump assembly, the valve memberincluding a valve body; an outside annular cavity formed in the valvebody; and a seal extending within the outside annular cavity, the sealdefining a tapered and circumferentially-extending surface adapted tosealingly engage a tapered surface of a valve seat of the inlet oroutlet valve; wherein the seal includes an annular bulbous protrusionfrom which the tapered and circumferentially-extending surface angularlyextends.

In an exemplary embodiment, the valve body defines a top surface;wherein the seal further includes a channel formed in the exteriorthereof; and wherein the channel is positioned between the top surfaceof the valve body and the annular bulbous protrusion.

In another exemplary embodiment, the outside annular cavity definesfirst and second angularly-extending surfaces; and wherein the valvemember further includes: an annular groove formed in the valve body atthe intersection of the first and second angularly-extending surfaces;and an annular element disposed in the annular groove and engaging theseal.

In yet another exemplary embodiment, the valve body defines first andsecond frusto-conical surfaces; wherein the second frusto-conicalsurface defined by the valve body extends angularly between: the firstfrusto-conical surface defined by the valve body; and the tapered andcircumferentially-extending surface of the seal; and wherein the valvemember further includes: a base from which the valve body extends,wherein the first frusto-conical surface of the valve body extendsangularly between the base and the second frusto-conical surface of thevalve body; and a plurality of circumferentially-spaced legs extendingfrom the base and away from the valve body, wherein the legs are adaptedto slidably engage another surface of the valve seat.

In certain exemplary embodiments, the base is a disk-shaped base thatdefines a circumferentially-extending convex surface.

In an exemplary embodiment, the valve member defines a first axisadapted to be coaxial with a second axis of the valve seat; wherein thefirst frusto-conical surface of the valve body defines a first anglefrom the first axis; and wherein the second frusto-conical surface ofthe valve body defines a second angle from the second axis.

In another exemplary embodiment, the first angle is greater than thesecond angle.

In yet another exemplary embodiment, the second angle is adapted to besubstantially equal to a taper angle defined by the tapered surface ofthe valve seat and measured from the second axis of the valve seat; andwherein the second angle is 50 degrees.

In certain exemplary embodiments, the valve body defines a first surfacearea adapted to contact the tapered surface of the valve seat; whereinthe seal defines a second surface area adapted to contact the taperedsurface of the valve seat; and wherein a ratio of the first surface areato the second surface ranges from about 0.9 to about 1.2.

In an exemplary embodiment, the ratio is about 1.

In another exemplary embodiment, the valve body defines a frusto-conicalsurface; wherein the tapered and circumferentially-extending surfacedefined by the seal extends angularly between the annular bulbousprotrusion and the frusto-conical surface defined by the valve body;wherein an offset distance is defined between the frusto-conical surfacedefined by the valve body, and at least a portion of the tapered andcircumferentially-extending surface defined by the seal.

In yet another exemplary embodiment, the offset distance extends in adirection that is perpendicular to at least the frusto-conical surface.

In certain exemplary embodiments, the offset distance ranges fromgreater than zero inches to about 0.1 inch.

In an exemplary embodiment, the frusto-conical surface defined by thevalve body and at least a portion of the tapered andcircumferentially-extending surface defined by the seal are spaced in aparallel relation; wherein an offset distance is defined between theparallel spacing between the frusto-conical surface defined by the valvebody, and the at least a portion of the tapered andcircumferentially-extending surface defined by the seal.

In another exemplary embodiment, the offset distance extends in adirection that is perpendicular to at least the frusto-conical surface.

In yet another exemplary embodiment, the offset distance ranges fromgreater than zero inches to about 0.1 inch.

In certain exemplary embodiments, the valve member defines a first axisadapted to be coaxial with a second axis of the valve seat; wherein afirst angle, as measured from the first axis, is defined by thefrusto-conical surface defined by the valve body; wherein a secondangle, as measured from the first axis, is defined by at least a portionof the tapered and circumferentially-extending surface defined by theseal; wherein the first and second angles are substantially equal; andwherein each of the first and second angles is adapted to besubstantially equal to a taper angle defined by the tapered surface ofthe valve seat and measured from the second axis of the valve seat.

In an exemplary embodiment, the seal further defines another tapered andcircumferentially-extending surface, which angularly extends from thefirst-mentioned tapered and circumferentially-extending surface definedby the seal.

In another exemplary embodiment, the extension of the another taperedand circumferentially-extending surface of the seal ends at, orproximate, the frusto-conical surface defined by the valve body.

In yet another exemplary embodiment, an annular contact portion of theseal is defined by the intersection between the first-mentioned and theanother tapered and circumferentially-extending surfaces of the seal,the annular contact portion including at least a portion of thefirst-mentioned tapered and circumferentially-extending surface of theseal.

In certain exemplary embodiments, the valve member defines a first axisadapted to be coaxial with a second axis of the valve seat; wherein afirst angle, as measured from the first axis, is defined by thefrusto-conical surface defined by the valve body; wherein a secondangle, as measured from the first axis, is defined by thefirst-mentioned tapered and circumferentially-extending surface definedby the seal; wherein a third angle, as measured from the first axis, isdefined by the another tapered and circumferentially-extending surfacedefined by the seal; wherein the first and second angles aresubstantially equal; wherein the third angle is greater than each of thefirst and second angles.

In an exemplary embodiment, the valve member includes a rupture discassembly engaged with the valve body.

In another exemplary embodiment, the valve member defines a first axisadapted to be coaxial with a second axis of the valve seat; wherein acounterbore is formed in the valve body and is generally coaxial withthe first axis, the counterbore including an enlarged-diameter portionand a reduced-diameter portion, the reduced-diameter portion defining afluid passage; wherein the counterbore defines an internal shoulderextending radially between the enlarged-diameter and reduced-diameterportions; and wherein the rupture disc assembly includes: a rupture discdisposed in the enlarged-diameter portion and engaging the internalshoulder; and an annular seal sealingly engaging at least the rupturedisc and the internal shoulder.

In yet another exemplary embodiment, the rupture disc includes anannular mounting portion disposed in the enlarged-diameter portion, anend of the annular mounting portion engaging the internal shoulder; adomed rupture portion about which the annular mounting portioncircumferentially extends; and an annular channel formed in the end ofthe annular mounting portion engaging the internal shoulder; wherein theannular seal extends within the annular channel and sealingly engages atleast the annular mounting portion and the internal shoulder.

In a third aspect, there is provided an inlet or outlet valve for areciprocating pump assembly, the inlet or outlet valve including a valveseat defining a first axis, the valve seat including a tapered surface;and a valve member adapted to be engaged with the valve seat, the valvemember defining a second axis that is adapted to be coaxial with thefirst axis, the valve member including: a valve body defining a firstsurface area adapted to contact the tapered surface of the valve seat;an outside annular cavity formed in the valve body; and a seal extendingwithin the outside annular cavity, the seal defining a second surfacearea adapted to contact the tapered surface of the valve seat; whereinthe ratio of the first surface area to the second surface area rangesfrom about 0.9 to about 1.2.

In an exemplary embodiment, the valve body defines first and secondfrusto-conical surfaces; wherein the seal defines a tapered andcircumferentially-extending surface adapted to sealingly engage thetapered surface of the valve seat; and wherein the second frusto-conicalsurface defined by the valve body extends angularly between: the firstfrusto-conical surface defined by the valve body; and the tapered andcircumferentially-extending surface of the seal.

In another exemplary embodiment, the seal further includes an annularbulbous protrusion from which the tapered andcircumferentially-extending surface angularly extends, the extensionending at, or proximate, the second frusto-conical surface defined bythe valve body.

In yet another exemplary embodiment, the valve body defines a topsurface; wherein the seal further includes a channel formed in theexterior thereof; and wherein the channel is positioned between the topsurface of the valve body and the annular bulbous protrusion.

In certain exemplary embodiments, the valve member further includes: abase from which the valve body extends, wherein the first frusto-conicalsurface of the valve body extends angularly between the base and thesecond frusto-conical surface of the valve body; and a plurality ofcircumferentially-spaced legs extending from the base and away from thevalve body, wherein the legs slidably engage another surface of thevalve seat.

In an exemplary embodiment, the first frusto-conical surface of thevalve body defines a first angle from the first axis; and wherein thesecond frusto-conical surface of the valve body defines a second anglefrom the second axis.

In another exemplary embodiment, the first angle is greater than thesecond angle.

In yet another exemplary embodiment, the second angle is adapted to besubstantially equal to a taper angle defined by the tapered surface ofthe valve seat and measured from the second axis of the valve seat; andwherein the second angle is 50 degrees.

In certain exemplary embodiments, the outside annular cavity definesfirst and second angularly-extending surfaces; and wherein the valvemember further includes: an annular groove formed in the valve body atthe intersection of the first and second angularly-extending surfaces;and an annular element disposed in the annular groove and engaging theseal.

In an exemplary embodiment, the seal defines a tapered andcircumferentially-extending surface adapted to sealingly engage thetapered surface of the valve seat; and wherein the seal includes anannular bulbous protrusion from which the tapered andcircumferentially-extending surface angularly extends.

In a fourth aspect, there is provided a valve member for a reciprocatingpump assembly, the valve member including a valve body including a firstfrusto-conical surface, the valve body defining an outside annularcavity formed therein; and a seal extending within the outside annularcavity, the seal including a first tapered andcircumferentially-extending surface adapted to sealingly engage atapered surface of a valve seat of the reciprocating pump assembly; andan annular bulbous protrusion from which the first tapered andcircumferentially-extending surface angularly extends, the first taperedand circumferentially-extending surface extending between the annularbulbous protrusion and the first frusto-conical surface of the valvebody.

In an exemplary embodiment, the seal further includes a channel formedin the exterior thereof, the channel being positioned between theannular bulbous protrusion of the seal and a top surface of the valvebody.

In another exemplary embodiment, the valve member defines a first axisadapted to be coaxial with a second axis defined by the valve seat; thefirst frusto-conical surface of the valve body defines a first angle, asmeasured from the first axis; and the tapered surface of the valve seatdefines a taper angle, as measured from the second axis, the taper anglebeing substantially equal to the first angle.

In yet another exemplary embodiment, the valve body further includes asecond frusto-conical surface, the first frusto-conical surface of thevalve body extending angularly between the second frusto-conical surfaceof the valve body and the first tapered and circumferentially-extendingsurface of the seal; and the second frusto-conical surface of the valvebody defines a second angle, as measured from the first axis, the secondangle being greater than the first angle.

In certain exemplary embodiments, the valve body and the seal definefirst and second surface areas, respectively, adapted to contact thetapered surface of the valve seat; and a ratio of the first surface areato the second surface area ranges from about 0.9 to about 1.2.

In an exemplary embodiment, an offset distance is defined between thefirst frusto-conical surface of the valve body and at least a portion ofthe first tapered and circumferentially-extending surface of the seal,the offset distance extending in a direction that is perpendicular to atleast the first frusto-conical surface of the valve body.

In another exemplary embodiment, the first frusto-conical surface of thevalve body defines a first angle, as measured from a first axis definedby the valve member, the first axis being adapted to be coaxial with asecond axis defined by the valve seat; the at least a portion of thefirst tapered and circumferentially-extending surface of the sealdefines a second angle, as measured from the first axis, the secondangle being substantially equal to the first angle; and the first andsecond angles are substantially equal to a taper angle defined by thetapered surface of the valve seat and measured from the second axis.

In yet another exemplary embodiment, the seal further includes a secondtapered and circumferentially-extending surface extending angularlybetween the first tapered and circumferentially-extending surface of theseal and the first frusto-conical surface of the valve body; and anannular contact portion defined by an intersection between the first andsecond tapered and circumferentially-extending surfaces, the annularcontact portion including at least a portion of the first tapered andcircumferentially-extending surface.

In certain exemplary embodiments, the first frusto-conical surface ofthe valve body defines a first angle, as measured from a first axisdefined by the valve member, the first axis being adapted to be coaxialwith a second axis defined by the valve seat; the first and secondtapered and circumferentially-extending surfaces of the seal definesecond and third angles, respectively, as measured from the first axis,the second angle being less than the third angle and substantially equalto the first angle.

In an exemplary embodiment, the valve body further defines a counterboreformed along a first axis of the valve body, the first axis beingadapted to be coaxial with a second axis defined by the valve seat, thecounterbore defining an enlarged diameter portion, a reduced-diameterportion, and an internal shoulder in the valve body, thereduced-diameter portion defining a fluid passage; and the valve memberfurther includes a rupture disc disposed in the enlarged-diameterportion of the counterbore and engaging the internal shoulder of thevalve body.

In a fifth aspect, there is provided a valve member for a reciprocatingpump assembly, the valve member including a valve body including a firstfrusto-conical surface, the valve body defining an outside annularcavity formed therein; and a seal extending within the outside annularcavity, the seal including a first tapered andcircumferentially-extending surface adapted to sealingly engage atapered surface of a valve seat of the reciprocating pump assembly;wherein an offset distance is defined between the first frusto-conicalsurface of the valve body and at least a portion of the first taperedand circumferentially-extending surface of the seal, the offset distanceextending in a direction that is perpendicular to at least the firstfrusto-conical surface of the valve body.

In an exemplary embodiment, the first frusto-conical surface of thevalve body defines a first angle, as measured from a first axis definedby the valve member, the first axis being adapted to be coaxial with asecond axis defined by the valve seat; the at least a portion of thefirst tapered and circumferentially-extending surface of the sealdefines a second angle, as measured from the first axis, the secondangle being substantially equal to the first angle; and the first andsecond angles are substantially equal to a taper angle defined by thetapered surface of the valve seat and measured from the second axis.

In another exemplary embodiment, the seal further includes a secondtapered and circumferentially-extending surface extending angularlybetween the first tapered and circumferentially-extending surface of theseal and the first frusto-conical surface of the valve body; and anannular contact portion defined by an intersection between the first andsecond tapered and circumferentially-extending surfaces, the annularcontact portion including at least a portion of the first tapered andcircumferentially-extending surface.

In yet another exemplary embodiment, the first frusto-conical surface ofthe valve body defines a first angle, as measured from a first axisdefined by the valve member, the first axis being adapted to be coaxialwith a second axis defined by the valve seat; the first and secondtapered and circumferentially-extending surfaces of the seal definesecond and third angles, respectively, as measured from the first axis,the second angle being less than the third angle and substantially equalto the first angle.

In certain exemplary embodiments, the seal further includes an annularbulbous protrusion from which the first tapered andcircumferentially-extending surface angularly extends, the first taperedand circumferentially-extending surface extending between the annularbulbous protrusion and the first frusto-conical surface of the valvebody; and a channel formed in the exterior thereof, the channel beingpositioned between the annular bulbous protrusion of the seal and a topsurface of the valve body.

In an exemplary embodiment, the valve member defines a first axisadapted to be coaxial with a second axis defined by the valve seat; thefirst frusto-conical surface of the valve body defines a first angle, asmeasured from the first axis; and the tapered surface of the valve seatdefines a taper angle, as measured from the second axis, the taper anglebeing substantially equal to the first angle.

In another exemplary embodiment, the valve body further includes asecond frusto-conical surface, the first frusto-conical surface of thevalve body extending angularly between the second frusto-conical surfaceof the valve body and the first tapered and circumferentially-extendingsurface of the seal; and the second frusto-conical surface of the valvebody defines a second angle, as measured from the first axis, the secondangle being greater than the first angle.

In yet another exemplary embodiment, the valve body and the seal definefirst and second surface areas, respectively, adapted to contact thetapered surface of the valve seat; and a ratio of the first surface areato the second surface area ranges from about 0.9 to about 1.2.

In certain exemplary embodiments, the valve body further defines acounterbore formed along a first axis of the valve body, the first axisbeing adapted to be coaxial with a second axis defined by the valveseat, the counterbore defining an enlarged diameter portion, areduced-diameter portion, and an internal shoulder in the valve body,the reduced-diameter portion defining a fluid passage.

In an exemplary embodiment, the valve member further includes a rupturedisc disposed in the enlarged-diameter portion of the counterbore andengaging the internal shoulder of the valve body; and an annular sealsealingly engaging at least the rupture disc and the internal shoulder.

Other aspects, features, and advantages will become apparent from thefollowing detailed description when taken in conjunction with theaccompanying drawings, which are a part of this disclosure and whichillustrate, by way of example, principles of the inventions disclosed.

DESCRIPTION OF FIGURES

The accompanying drawings facilitate an understanding of the variousembodiments.

FIG. 1 is an elevational view of a reciprocating pump assembly accordingto an exemplary embodiment, the pump assembly includes a fluid end.

FIG. 2 is a section view of the fluid end of FIG. 1 according to anexemplary embodiment, the fluid end including a fluid end block andinlet and outlet valves, the inlet and outlet valves each including avalve seat.

FIG. 3 is an enlarged view of a portion of the section view of FIG. 2,according to an exemplary embodiment.

FIG. 4 is a section view of respective portions of the valve seat andthe fluid end block, according to another exemplary embodiment.

FIG. 5 is a section view of respective portions of the valve seat andfluid end block, according to yet another exemplary embodiment.

FIG. 6 is a section view of a valve according to another exemplaryembodiment, the valve including a valve seat.

FIG. 7 is a perspective view of the valve seat of FIG. 6, according toan exemplary embodiment.

FIG. 8 is a sectional view of the valve seat of FIGS. 6 and 7, accordingto an exemplary embodiment.

FIG. 9 is a sectional view of the valve of FIG. 6 disposed within thefluid end block of FIG. 2, according to an exemplary embodiment.

FIG. 10 is a sectional view of a valve according to an exemplaryembodiment, the valve including a valve seat and a valve member.

FIG. 11 is an enlarged view of a portion of the valve member of FIG. 10,according to another exemplary embodiment.

FIG. 12 is a view of experimental steel contact pressures experienced bya finite element model of the valve of FIG. 10, according to anexemplary experimental embodiment.

FIG. 13 is a view of experimental stresses experienced by a finiteelement model of the valve of FIG. 10, according to an exemplaryexperimental embodiment.

FIG. 14 is a view of experimental urethane contact pressures experiencedby a finite element model of the valve of FIG. 10, according to anexemplary experimental embodiment.

FIG. 15 is a perspective view of a valve member according to anexemplary embodiment.

FIG. 16 is an elevational view of the valve member of FIG. 15.

FIG. 17 is a sectional view of the valve member of FIGS. 15 and 16 takenalong line 17-17 of FIG. 16, according to an exemplary embodiment.

FIG. 18 is an enlarged view of a portion of FIG. 17, according to anexemplary embodiment.

FIG. 19 is a perspective view of a valve member according to anexemplary embodiment.

FIG. 20 is an elevational view of the valve member of FIG. 19.

FIG. 21 is a sectional view of the valve member of FIGS. 19 and 20 takenalong line 21-21 of FIG. 20, according to an exemplary embodiment.

FIG. 22 is a perspective view of a valve member according to anexemplary embodiment.

FIG. 23 is an elevational view of the valve member of FIG. 22.

FIG. 24 is a sectional view of the valve member of FIGS. 22 and 23 takenalong line 24-24 of FIG. 23, according to an exemplary embodiment.

FIG. 25 is an enlarged view of a portion of FIG. 24, according to anexemplary embodiment.

FIG. 26 is a perspective view of a valve member according to anexemplary embodiment.

FIG. 27 is an elevational view of the valve member of FIG. 26.

FIG. 28 is a sectional view of the valve member of FIGS. 26 and 27 takenalong line 28-28 of FIG. 27, according to an exemplary embodiment.

FIG. 29 is an enlarged sectional view of a valve member, according to anexemplary embodiment.

FIG. 30 is another enlarged sectional view of a valve member, accordingto an exemplary embodiment.

DETAILED DESCRIPTION

In an exemplary embodiment, as illustrated in FIG. 1, a reciprocatingpump assembly is generally referred to by the reference numeral 10 andincludes a power end portion 12 and a fluid end portion 14 operablycoupled thereto. The power end portion 12 includes a housing 16 in whicha crankshaft (not shown) is disposed, the crankshaft being operablycoupled to an engine or motor (not shown), which is adapted to drive thecrankshaft. The fluid end portion 14 includes a fluid end block 18,which is connected to the housing 16 via a plurality of stay rods 20.The fluid end block 18 includes a fluid inlet passage 22 and a fluidoutlet passage 24, which are spaced in a parallel relation. A pluralityof cover assemblies 26, one of which is shown in FIG. 1, is connected tothe fluid end block 18 opposite the stay rods 20. A plurality of coverassemblies 28, one of which is shown in FIG. 1, is connected to thefluid end block 18 opposite the fluid inlet passage 22. A plunger rodassembly 30 extends out of the housing 16 and into the fluid end block18. In several exemplary embodiments, the pump assembly 10 isfreestanding on the ground, is mounted to a trailer that can be towedbetween operational sites, or is mounted to a skid.

In an exemplary embodiment, as illustrated in FIG. 2 with continuingreference to FIG. 1, the plunger rod assembly 30 includes a plunger 32,which extends through a bore 34 formed in the fluid end block 18, andinto a pressure chamber 36 formed in the fluid end block 18. In severalexemplary embodiments, a plurality of parallel-spaced bores may beformed in the fluid end block 18, with one of the bores being the bore34, a plurality of pressure chambers may be formed in the fluid endblock 18, with one of the pressure chambers being the pressure chamber36, and a plurality of parallel-spaced plungers may extend throughrespective ones of the bores and into respective ones of the pressurechambers, with one of the plungers being the plunger 32. At least thebore 34, the pressure chamber 36, and the plunger 32 together may becharacterized as a plunger throw. In several exemplary embodiments, thereciprocating pump assembly 10 includes three plunger throws (i.e., atriplex pump assembly), or includes four or more plunger throws.

As shown in FIG. 2, the fluid end block 18 includes inlet and outletfluid passages 38 and 40 formed therein, which are generally coaxialalong a fluid passage axis 42. Under conditions to be described below,fluid is adapted to flow through the inlet and outlet fluid passages 38and 40 and along the fluid passage axis 42. The fluid inlet passage 22is in fluid communication with the pressure chamber 36 via the inletfluid passage 38. The pressure chamber 36 is in fluid communication withthe fluid outlet passage 24 via the outlet fluid passage 40. The fluidinlet passage 38 includes an enlarged-diameter portion 38 a and areduced-diameter portion 38 b extending downward therefrom. Theenlarged-diameter portion 38 a defines a tapered internal shoulder 43and thus a frusto-conical surface 44 of the fluid end block 18. Thereduced-diameter portion 38 b defines an inside surface 46 of the fluidend block 18. Similarly, the fluid outlet passage 40 includes anenlarged-diameter portion 40 a and a reduced-diameter portion 40 bextending downward therefrom. The enlarged-diameter portion 40 a definesa tapered internal shoulder 48 and thus a frusto-conical surface 50 ofthe fluid end block 18. The reduced-diameter portion 40 b defines aninside surface 52 of the fluid end block 18.

An inlet valve 54 is disposed in the fluid passage 38, and engages atleast the frusto-conical surface 44 and the inside surface 46.Similarly, an outlet valve 56 is disposed in the fluid passage 40, andengages at least the frusto-conical surface 50 and the inside surface52. In an exemplary embodiment, each of valves 54 and 56 is aspring-loaded valve that is actuated by a predetermined differentialpressure thereacross.

A counterbore 58 is formed in the fluid end block 18, and is generallycoaxial with the fluid passage axis 42. The counterbore 58 defines aninternal shoulder 58 a and includes an internal threaded connection 58 badjacent the internal shoulder 58 a. A counterbore 60 is formed in thefluid end block 18, and is generally coaxial with the bore 34 along anaxis 62. The counterbore 60 defines an internal shoulder 60 a andincludes an internal threaded connection 60 b adjacent the internalshoulder 60 a. In several exemplary embodiments, the fluid end block 18may include a plurality of parallel-spaced counterbores, one of whichmay be the counterbore 58, with the quantity of counterbores equalingthe quantity of plunger throws included in the pump assembly 10.Similarly, in several exemplary embodiments, the fluid end block 18 mayinclude another plurality of parallel-spaced counterbores, one of whichmay be the counterbore 60, with the quantity of counterbores equalingthe quantity of plunger throws included in the pump assembly 10.

A plug 64 is disposed in the counterbore 58, engaging the internalshoulder 58 a and sealingly engaging an inside cylindrical surfacedefined by the reduced-diameter portion of the counterbore 58. Anexternal threaded connection 66 a of a fastener 66 is threadably engagedwith the internal threaded connection 58 b of the counterbore 58 so thatan end portion of the fastener 66 engages the plug 64. As a result, thefastener 66 sets or holds the plug 64 in place against the internalshoulder 58 a defined by the counterbore 58, thereby maintaining thesealing engagement of the plug 64 against the inside cylindrical surfacedefined by the reduced-diameter portion of the counterbore 58. The coverassembly 28 shown in FIGS. 1 and 2 includes at least the plug 64 and thefastener 66. In an exemplary embodiment, the cover assembly 28 may bedisconnected from the fluid end block 18 to provide access to, forexample, the counterbore 58, the pressure chamber 36, the plunger 32,the fluid passage 40 or the outlet valve 56. The cover assembly 28 maythen be reconnected to the fluid end block 18 in accordance with theforegoing. In several exemplary embodiments, the pump assembly 10 mayinclude a plurality of plugs, one of which is the plug 64, and aplurality of fasteners, one of which is the fastener 66, with therespective quantities of plugs and fasteners equaling the quantity ofplunger throws included in the pump assembly 10.

A plug 68 is disposed in the counterbore 60, engaging the internalshoulder 60 a and sealingly engaging an inside cylindrical surfacedefined by the reduced-diameter portion of the counterbore 60. In anexemplary embodiment, the plug 68 may be characterized as a suctioncover. An external threaded connection 70 a of a fastener 70 isthreadably engaged with the internal threaded connection 60 b of thecounterbore 60 so that an end portion of the fastener 70 engages theplug 68. As a result, the fastener 70 sets or holds the plug 68 in placeagainst the internal shoulder 60 a defined by the counterbore 60,thereby maintaining the sealing engagement of the plug 68 against theinside cylindrical surface defined by the reduced-diameter portion ofthe counterbore 60. The cover assembly 26 shown in FIGS. 1 and 2includes at least the plug 68 and the fastener 70. In an exemplaryembodiment, the cover assembly 26 may be disconnected from the fluid endblock 18 to provide access to, for example, the counterbore 60, thepressure chamber 36, the plunger 32, the fluid passage 38, or the inletvalve 54. The cover assembly 26 may then be reconnected to the fluid endblock in accordance with the foregoing. In several exemplaryembodiments, the pump assembly 10 may include a plurality of plugs, oneof which is the plug 68, and a plurality of fasteners, one of which isthe fastener 70, with the respective quantities of plugs and fastenersequaling the quantity of plunger throws included in the pump assembly10.

A valve spring retainer 72 is disposed in the enlarged-diameter portion38 a of the fluid passage 38. The valve spring retainer 72 is connectedto the end portion of the plug 68 opposite the fastener 70. In anexemplary embodiment, and as shown in FIG. 2, the valve spring retainer72 is connected to the plug 68 via a hub 74, which is generally coaxialwith the axis 62.

In an exemplary embodiment, as illustrated in FIG. 3 with continuingreference to FIGS. 1 and 2, the inlet valve 54 includes a valve seat 76and a valve member 78 engaged therewith. The valve seat 76 includes aseat body 80 having an enlarged-diameter portion 82 at one end thereof.The enlarged-diameter portion 82 of the seat body 80 is disposed in theenlarged-diameter portion 38 a of the fluid passage 38. A bore 83 isformed through the seat body 80. The valve seat 76 has a valve seat axis84, which is aligned with the fluid passage axis 42 when the inlet valve54 is disposed in the fluid passage 38, as shown in FIG. 3. Underconditions to be described below, fluid flows through the bore 83 andalong the valve seat axis 84. The bore 83 defines an inside surface 85of the seat body 80. An outside surface 86 of the seat body 80 contactsthe inside surface 46 defined by the fluid passage 38. A sealingelement, such as an O-ring 88, is disposed in an annular groove 90formed in the outside surface 86. The O-ring 88 sealingly engages theinside surface 46. The enlarged-diameter portion 82 includes a taperedexternal shoulder 91 and thus defines a frusto-conical surface 92, whichextends angularly upward from the outside surface 86. The portion 82further defines a cylindrical surface 94, which extends axially upwardfrom the extent of the frusto-conical surface 92. The frusto-conicalsurface 92 is axially disposed between the outside surface 86 and thecylindrical surface 94. The portion 82 further defines a tapered surface96, which extends angularly upward from the inside surface 85, as viewedin FIG. 3. In an exemplary embodiment, the tapered surface 96 extends atan angle from the valve seat axis 84. The seat body 80 of the valve seat76 is disposed within the reduced-diameter portion 38 b of the fluidpassage 38 so that the outside surface 86 of the seat body 80 engagesthe inside surface 46 of the fluid end block 18. In an exemplaryembodiment, the seat body 80 forms an interference fit, or is press fit,in the portion 38 b of the fluid passage 38 so that the valve seat 76 isprevented from being dislodged from the fluid passage 38.

The valve member 78 includes a central stem 98, from which a valve body100 extends radially outward. An outside annular cavity 102 is formed inthe valve body 100. A seal 104 extends within the cavity 102, and isadapted to sealingly engage the tapered surface 96 of the valve seat 76,under conditions to be described below. A plurality ofcircumferentially-spaced legs 106 extend angularly downward from thecentral stem 98 (as viewed in FIG. 3), and slidably engage the insidesurface 85 of the seat body 80. In several exemplary embodiments, theplurality of legs 106 may include two, three, four, five, or greaterthan five, legs 106. A lower end portion of a spring 108 is engaged withthe top of the valve body 100 opposite the central stem 98. The valvemember 78 is movable, relative to the valve seat 76 and thus the fluidend block 18, between a closed position (shown in FIG. 3) and an openposition (not shown), under conditions to be described below.

In an exemplary embodiment, the seal 104 is molded in place in the valvebody 100. In an exemplary embodiment, the seal 104 is preformed and thenattached to the valve body 100. In several exemplary embodiments, theseal 104 is composed of one or more materials such as, for example, adeformable thermoplastic material, a urethane material, afiber-reinforced material, carbon, glass, cotton, wire fibers, cloth,and/or any combination thereof. In an exemplary embodiment, the seal 104is composed of a cloth which is disposed in a thermoplastic material,and the cloth may include carbon, glass, wire, cotton fibers, and/or anycombination thereof. In several exemplary embodiments, the seal 104 iscomposed of at least a fiber-reinforced material, which prevents, or atleast reduces, delamination. In an exemplary embodiment, the seal 104has a hardness of 95 A durometer or greater, or a hardness of 69 Ddurometer or greater. In several exemplary embodiments, the valve body100 is much harder and/or more rigid than the seal 104.

The outlet valve 56 is identical to the inlet valve 54 and thereforewill not be described in further detail. Features of the outlet valve 56that are identical to corresponding features of the inlet valve 54 willbe given the same reference numerals as that of the inlet valve 54. Thevalve seat axis 84 of the outlet valve 56 is aligned with each of thefluid passage axis 42 and the valve seat axis 84 of the inlet valve 54.The outlet valve 56 is disposed in the fluid passage 40, and engages thefluid end block 18, in a manner that is identical to the manner in whichthe inlet valve 54 is disposed in the fluid passage 38, and engages thefluid end block 18, with one exception. This one exception involves thespring 108 of the outlet valve 56; more particularly, the upper portionof the spring 108 of the outlet valve 56 is compressed against thebottom of the plug 64, rather than being compressed against a componentthat corresponds to the valve spring retainer 72, against which theupper portion of the spring 108 of the inlet valve 54 is compressed.

In operation, in an exemplary embodiment, with continuing reference toFIGS. 1-3, the plunger 32 reciprocates within the bore 34, reciprocatingin and out of the pressure chamber 36. That is, the plunger 32 movesback and forth horizontally, as viewed in FIG. 2, away from and towardsthe fluid passage axis 42. In an exemplary embodiment, the engine ormotor (not shown) drives the crankshaft (not shown) enclosed within thehousing 16, thereby causing the plunger 32 to reciprocate within thebore 34 and thus in and out of the pressure chamber 36.

As the plunger 32 reciprocates out of the pressure chamber 36, the inletvalve 54 is opened. More particularly, as the plunger 32 moves away fromthe fluid passage axis 42, the pressure inside the pressure chamber 36decreases, creating a differential pressure across the inlet valve 54and causing the valve member 78 to move upward, as viewed in FIGS. 2 and3, relative to the valve seat 76 and the fluid end block 18. As a resultof the upward movement of the valve member 78, the spring 108 iscompressed between the valve body 100 and the valve spring retainer 72,the seal 104 disengages from the tapered surface 96, and the inlet valve54 is thus placed in its open position. Fluid in the fluid inlet passage22 flows along the fluid passage axis 42 and through the fluid passage38 and the inlet valve 54, being drawn into the pressure chamber 36. Toflow through the inlet valve 54, the fluid flows through the bore 83 ofthe valve seat 76 and along the valve seat axis 84. During the fluidflow through the inlet valve 54 and into the pressure chamber 36, theoutlet valve 56 is in its closed position, with the seal 104 of thevalve member 78 of the outlet valve 56 engaging the tapered surface 96of the valve seat 76 of the outlet valve 56. Fluid continues to be drawninto the pressure chamber 36 until the plunger 32 is at the end of itsstroke away from the fluid passage axis 42. At this point, thedifferential pressure across the inlet valve 54 is such that the spring108 of the inlet valve 54 is not further compressed, or begins todecompress and extend, forcing the valve member 78 of the inlet valve 54to move downward, as viewed in FIGS. 2 and 3, relative to the valve seat76 and the fluid end block 18. As a result, the inlet valve 54 is placedin, or begins to be placed in, its closed position, with the seal 104sealingly engaging, or at least moving towards, the tapered surface 96.

As the plunger 32 moves into the pressure chamber 36 and thus towardsthe fluid passage axis 42, the pressure within the pressure chamber 36begins to increase. The pressure within the pressure chamber 36continues to increase until the differential pressure across the outletvalve 56 exceeds a predetermined set point, at which point the outletvalve 56 opens and permits fluid to flow out of the pressure chamber 36,along the fluid passage axis 42 and through the fluid passage 40 and theoutlet valve 56, and into the fluid outlet passage 24. As the plunger 32reaches the end of its stroke towards the fluid passage axis 42 (i.e.,its discharge stroke), the inlet valve 54 is in, or is placed in, itsclosed position, with the seal 104 sealingly engaging the taperedsurface 96.

The foregoing is repeated, with the reciprocating pump assembly 10pressurizing the fluid as the fluid flows from the fluid inlet passage22 to the fluid outlet passage 24 via the pressure chamber 36. In anexemplary embodiment, the pump assembly 10 is a single-actingreciprocating pump, with fluid being pumped across only one side of theplunger 32.

In an exemplary embodiment, during the above-described operation of thereciprocating pump assembly 10, the taper of each of the surfaces 44 and92 balances the loading forces applied thereagainst. In an exemplaryembodiment, the loading is distributed across the surface 44 and 92,reducing stress concentrations. In an exemplary embodiment, the stressesin the valve seat 76, in the vicinity of the fillet interface betweenthe surfaces 86 and the 92, are balanced with the stresses in the fluidend block 18, in the vicinity of the round interface between thesurfaces 46 and 44. As a result, these stresses are reduced. In anexemplary embodiment, the taper of each of the surfaces 44 and 92permits the outside diameter of the seat body 80 of the inlet valve 54to be reduced, thereby also permitting a relatively smaller serviceport, as well as relatively smaller cross-bore diameters within thefluid end block 18. In an exemplary embodiment, the taper of each of thesurfaces 44 and 92 reduces the extraction force necessary to remove thevalve seat 76 from the fluid passage 38.

In an exemplary embodiment, as illustrated in FIG. 4 with continuingreference to FIGS. 1-3, a taper angle 110 is defined by the taperedexternal shoulder 91 and thus the frusto-conical surface 92. A taperangle 112 is defined by the tapered internal shoulder 43 and thus thefrusto-conical surface 44. Each of the taper angles 110 and 112 may bemeasured from the fluid passage axis 42 and the valve seat axis 84aligned therewith. In an exemplary embodiment, the taper angles 110 and112 are equal, and range from about 10 degrees to about 45 degreesmeasured from the fluid passage axis 42 and the valve seat axis 84aligned therewith. In an exemplary embodiment, the taper angles 110 and112 range from about 20 degrees to 40 degrees measured from the fluidpassage axis 42 and the valve seat axis 84 aligned therewith. In anexemplary embodiment, the taper angles 110 and 112 range from about 25to 35 degrees measured from the fluid passage axis 42 and the valve seataxis 84 aligned therewith. In an exemplary embodiment, the taper angles110 and 112 are equal, and each of the taper angles 110 and 112 is about30 degrees measured from the fluid passage axis 42 and the valve seataxis 84 aligned therewith. In an exemplary embodiment, the taper angles110 and 112 are not equal. As shown in FIG. 4, a frusto-conical gap orregion 114 may be defined between the surfaces 44 and 92. Moreover, aradial clearance 116 is defined between the outside cylindrical surface94 of the valve seat 76 and an inside surface 118 of the fluid end block18, the surface 118 being defined by the enlarged-diameter portion 38 aof the fluid passage 38. In an exemplary embodiment, the region 114 maybe omitted and the surface 92 may abut the surface 44. In an exemplaryembodiment, material may be disposed in the region 114 to absorb,transfer and/or distribute loads between the surfaces 44 and 92.

As shown in FIG. 4, at least the end portion of the body 80 opposite theenlarged-diameter portion 82 is tapered at a taper angle 120 from thefluid passage axis 42 and the valve seat axis 84 aligned therewith. Inan exemplary embodiment, the taper angle 120 ranges from about 0 degreesto about 5 degrees measured from the fluid passage axis 42 and the valveseat axis 84 aligned therewith. In an exemplary embodiment, the taperangle 120 ranges from about 1 degree to about 4 degrees measured fromthe fluid passage axis 42 and the valve seat axis 84 aligned therewith.In an exemplary embodiment, the taper angle 120 ranges from about 1degree to about 3 degrees measured from the fluid passage axis 42 andthe valve seat axis 84 aligned therewith. In an exemplary embodiment,the taper angle 120 is about 2 degrees measured from the fluid passageaxis 42 and the valve seat axis 84 aligned therewith. In an exemplaryembodiment, the taper angle 120 is about 1.8 degrees measured from thefluid passage axis 42 and the valve seat axis 84 aligned therewith. Inan exemplary embodiment, instead of, or in addition to the end portionof the body 80 opposite the enlarged-diameter portion 82 being tapered,the inside surface 46 of the fluid end block 18 is tapered at the taperangle 120. In an exemplary embodiment, an interference fit may be formedbetween the body 80 and the inside surface 46, thereby holding the valveseat 76 in place in the fluid end block. In several exemplaryembodiments, instead of using an interference fit in the fluid passage38, a threaded connection, a threaded nut, and/or a snap-fit mechanismmay be used to hold the valve seat 76 in place in the fluid end block18.

In an exemplary embodiment, during the operation of the pump assembly 10using the embodiment of the inlet valve 54 illustrated in FIG. 4, thesurfaces 92 and 44 provide load balancing, with loading on theenlarged-diameter portion 82 of the valve seat 76 being distributed andtransferred to the surface 44 of the fluid end block 18, via either thepressing of the surface 92 against the surface 44 or intermediatematerial(s) disposed therebetween.

In an exemplary embodiment, as illustrated in FIG. 5 with continuingreference to FIGS. 1-4, a fillet surface 122 of the fluid end block 18is defined by the enlarged-diameter portion 38 a of the fluid passage38. The fillet surface 122 extends between the frusto-conical surface 44and the inside surface 118. As shown in FIG. 5, each of thefrusto-conical surfaces 92 and 44 is tapered at a taper angle 123, whichmay be measured from the fluid passage axis 42 and the valve seat axis84 aligned therewith. In an exemplary embodiment, the taper angle 123ranges from about 10 degrees to about 45 degrees measured from the fluidpassage axis 42 and the valve seat axis 84 aligned therewith. In anexemplary embodiment, the taper angle 123 ranges from about greater than10 degrees to about 30 degrees measured from the fluid passage axis 42and the valve seat axis 84 aligned therewith. In an exemplaryembodiment, the taper angle 123 ranges from about 12 degrees to about 20degrees measured from the fluid passage axis 42 and the valve seat axis84 aligned therewith. In an exemplary embodiment, the taper angle 123 isabout 14 degrees measured from the fluid passage axis 42 and the valveseat axis 84 aligned therewith. In an exemplary embodiment, the surface92 and 44 may be tapered at respective angles that are not equal. Thesurface 92 abuts the surface 44. As shown in FIG. 5, the groove 90 andthe O-ring 88 are omitted in favor of an annular groove 124 and anO-ring 126, respectively. The annular groove 124 is formed in thefrusto-conical surface 92, and the O-ring ring 126 is disposed in theannular groove 124. The O-ring 126 sealingly engages the frusto-conicalsurface 44.

In an exemplary embodiment, during the operation of the pump assembly 10using the embodiment of the inlet valve 54 illustrated in FIG. 5, loadsapplied to the valve seat 76 are distributed and transferred to thefluid end block 18 via, at least in part, the load balancing provided bythe abutment of the surface 92 against the surface 44.

In an exemplary embodiment, during the operation of the pump assembly 10using any of the foregoing embodiments of the inlet valve 54, downwardlydirected axial loads along the fluid passage axis 42 are applied againstthe top of the valve body 100. This loading is usually greatest as theplunger 32 moves towards the fluid passage axis 42 and the outlet valve56 opens and permits fluid to flow out of the pressure chamber 36,through the fluid passage 40 and the outlet valve 56, and into the fluidoutlet passage 24. As the plunger 32 reaches the end of its stroketowards the fluid passage axis 42 (its discharge stroke), the inletvalve 54 is in, or is placed in, its closed position, and the loadingapplied to the top of the valve body 100 is transferred to the seal 104via the valve body 100. The loading is then transferred to the valveseat 76 via the seal 104, and then is distributed and transferred to thetapered internal shoulder 43 of the fluid end block 18 via either theengagement of the surface 92 against the surface 44 or intermediatematerial(s) disposed therebetween. The tapering of the surfaces 92 and44 facilitates this distribution and transfer of the downwardly directedaxial loading to the fluid end block 18 in a balanced manner, therebyreducing stress concentrations in the fluid end block 18 and the valveseat 76.

In an exemplary embodiment, as illustrated in FIGS. 6-8 with continuingreference to FIGS. 1-5, an inlet valve is generally referred to by thereference numeral 128 and includes several parts that are identical tocorresponding parts of the inlet valve 54, which identical parts aregiven the same reference numerals. The inlet valve 128 includes a valveseat 129. The valve seat 129 includes several features that areidentical to corresponding features of the valve seat 76, whichidentical features are given the same reference numerals. An annularnotch 130 is formed in the valve seat 128 at the intersection of thesurfaces 86 and 92.

As shown in FIG. 8, a taper angle 132 is defined by the external taperedshoulder 91 and thus the frusto-conical surface 92. The taper angle 132may be measured from the valve seat axis 84. In an exemplary embodiment,the taper angle 132 is about 30 degrees measured from the valve seataxis 84. In an exemplary embodiment, the taper angle 132 ranges fromabout 10 degrees to about 45 degrees measured from the valve seat axis84. In an exemplary embodiment, the taper angle 132 ranges from about 20degrees to about 40 degrees measured from the valve seat axis 84. In anexemplary embodiment, the taper angle 132 ranges from about 25 to about35 degrees measured from the valve seat axis 84. The cylindrical surface94 defined by the enlarged-diameter portion 82 of the valve seat 129defines an outside diameter 134. In an exemplary embodiment, the outsidediameter 134 is about 5 inches. In an exemplary embodiment, the outsidediameter 134 is about 5.06 inches. The inside surface 85 of the seatbody 80 defined by the bore 83 formed therethrough defines an insidediameter 136. In an exemplary embodiment, the inside diameter 136 rangesfrom about 3 inches to about 3.5 inches. In an exemplary embodiment, theinside diameter 136 is about 3.27 inches. An annular surface 138 of theseat body 80 is defined by the annular groove 90. A groove diameter 140is defined by the annular surface 138. In an exemplary embodiment, thegroove diameter 140 ranges from about 4 inches to about 4.5 inches. Inan exemplary embodiment, the groove diameter 140 is about 4.292 inches.In an exemplary embodiment, an outside diameter 142 is defined by theoutside surface 86 of the seat body 80 at an axial location therealongadjacent the annular notch 130, or at least in the vicinity of theintersection between the surfaces 86 and 92. In an exemplary embodiment,the outside diameter 142 ranges from about 4 inches to about 5 inches.In an exemplary embodiment, the outside diameter 142 ranges from about4.5 inches to about 5 inches. In an exemplary embodiment, the outsidediameter 142 ranges from about 4.5 inches to about 4.6 inches. In anexemplary embodiment, the outside diameter 142 is about 4.565 inches.The outside surface 86 is tapered radially inward beginning at the axiallocation of the outside diameter 142 and ending at the end of the body80 opposite the enlarged-diameter portion 82, thereby defining a taperangle 144 from the valve seat axis 84. In an exemplary embodiment, thetaper angle 144 ranges from about 0 degrees to about 5 degrees measuredfrom the valve seat axis 84. In an exemplary embodiment, the taper angle144 ranges from greater than 0 degrees to about 5 degrees measured fromthe valve seat axis 84. In an exemplary embodiment, the taper angle 144is about 2 degrees measured from the valve seat axis 84. In an exemplaryembodiment, the taper angle 144 is about 1.8 degrees measured from thevalve seat axis 84.

In an exemplary embodiment, as illustrated in FIG. 9 with continuingreference to FIGS. 1-8, the inlet valve 54 is omitted from the pumpassembly 10 in favor of the inlet valve 128, which is disposed in thefluid passage 38. The tapered external shoulder 91 of the valve seat 129engages the tapered internal shoulder 43 of the fluid end block 18.Thus, the frusto-conical surface 92 engages the frusto-conical surface44. In an exemplary embodiment, the tapered internal shoulder 43 definesa taper angle from the fluid passage axis 42 that is equal to the taperangle 132. In an exemplary embodiment, the tapered internal shoulder 43defines a taper angle that is equal to the taper angle 132, and thetaper angle 132 ranges from about 10 degrees to about 45 degreesmeasured from the valve seat axis 84. In an exemplary embodiment, thetapered angle 132 ranges from about 20 degrees to 45 degrees measuredfrom the valve seat axis 84. In an exemplary embodiment, the taperedangle 132 ranges from about 25 degrees to 35 degrees measured from thevalve seat axis 84. In an exemplary embodiment, the tapered internalshoulder 43 defines a taper angle that is equal to the taper angle 132,and the taper angle 132 is about 30 degrees measured from the valve seataxis 84. The O-ring 88 sealingly engages the inside surface 46 of thefluid end block 18. The outside surface 86 of the body 80 of the valveseat 129 of the inlet valve 128 engages the inside surface 46 of thefluid end block 18. In an exemplary embodiment, at least thereduced-diameter portion 38 b of the fluid passage 38 is tapered suchthat an inside diameter 146 defined by the portion 38 b decreases alongthe fluid passage axis 42 in an axial direction away from theenlarged-diameter portion 38 a. In an exemplary embodiment, at an axiallocation corresponding to the intersection between the surfaces 46 and44, the inside diameter 146 ranges from about 4 inches to about 5inches. In an exemplary embodiment, at an axial location correspondingto the intersection between the surfaces 46 and 44, the inside diameter146 ranges from about 4.5 inches to about 5 inches. In an exemplaryembodiment, at an axial location corresponding to the intersectionbetween the surfaces 46 and 44, the inside diameter 146 ranges fromabout 4.5 inches to about 4.6 inches. In an exemplary embodiment, at anaxial location corresponding to the intersection between the surfaces 46and 44, the inside diameter 146 is about 4.553 inches. In an exemplaryembodiment, an interference fit is formed between the outside surface 86and the inside surface 46, thereby preventing the valve seat 129 frombeing dislodged from the fluid passage 38.

In an exemplary embodiment, the operation of the inlet valve 129 duringthe operation of the pump assembly 10 is identical to the operation ofthe inlet valve 54. Therefore, the operation of the inlet valve 129during the operation of the pump assembly 10 will not be described indetail.

In an exemplary embodiment, the inlet valve 54 may be omitted from thepump assembly 10 in favor of the inlet valve 128, and the outlet valve56 may be omitted from the pump assembly 10 in favor of an outlet valvethat is identical to the inlet valve 128. In an exemplary embodiment,the operation of the pump assembly 10 using the inlet valve 128, and anoutlet valve that is identical to the inlet valve 128, is identical tothe above-described operation of the pump assembly 10 using the inletvalve 54 and the outlet valve 56.

In an exemplary embodiment, as illustrated in FIGS. 10 and 11 withcontinuing reference to FIGS. 1-9, an inlet valve is generally referredto by the reference numeral 150 and includes several parts that areidentical to corresponding parts of the inlet valve 54, which identicalparts are given the same reference numerals. The inlet valve 150includes a valve seat 152 and a valve member 154.

The valve seat 152 includes several features that are identical tocorresponding features of the valve seat 76, which identical featuresare given the same reference numerals. In contrast to the valve seat 76,however, and as shown in FIG. 10, the valve seat 152 does not includethe external tapered shoulder 91 and thus does not include thefrusto-conical surface 92. Instead, the valve seat 152 includes anexternal shoulder 156, which defines an axially-facing andcircumferentially-extending surface 158. Alternatively, in severalexemplary embodiments, the valve seat 152 may be described as having theexternal tapered shoulder 91, but the value of the taper angle 132defined by the external tapered shoulder 91 is 90 degrees. Moreover, thesurface area of the tapered surface 96 is increased; in particular, theportion of the surface area of the tapered surface 96 that is adapted toundergo steel-to-steel contact is about doubled (2× to 2×).

An annular notch 160 is formed in the valve seat 152 at the intersectionof the surfaces 86 and 158. A taper angle 162 is defined by the taperedsurface 96. The taper angle 162 may be measured from the valve seat axis84. In an exemplary embodiment, the taper angle 162 is about 50 degreesmeasured from the vertically-extending valve seat axis 84 (40 degreesfrom any horizontal line as viewed in FIG. 10). In an exemplaryembodiment, the taper angle 162 ranges from about 40 degrees to about 60degrees measured from the valve seat axis 84 (50 degrees to about 30degrees from any horizontal line as viewed in FIG. 10). In an exemplaryembodiment, the taper angle 162 ranges from about 45 degrees to about 55degrees measured from the valve seat axis 84 (45 degrees to about 35degrees from any horizontal line as viewed in FIG. 10).

The valve member 154 includes a central disk-shaped central base 164,which defines an outside circumferentially-extending convex surface 166.A valve body 168 extends axially upwards from the base 164, along thevalve seat axis 84. The valve body 168 also extends radially outwardfrom the valve seat axis 84. An outside annular cavity 170 is formed inthe valve body 168. A generally tapered and circumferentially-extendingsurface 172, which extends angularly downward, is defined by the outsideannular cavity 170. A generally tapered and circumferentially-extendingsurface 174, which extends angularly upward, is also defined by theoutside annular cavity. A lower circumferentially-extending channel 176is formed in the surface 174. Upper circumferentially-extending channels178 a and 178 b are formed in the surface 172. An annular groove 180 isformed in the valve body 168 at the intersection between the surfaces172 and 174. An annular element, such as an O-ring 182, is disposed inthe annular groove 180.

A seal 184 extends within the outside annular cavity 170, and is adaptedto sealingly engage the tapered surface 96 of the valve seat 152. Theseal 184 extends within the channels 176, 178 a, and 178 b. The O-ring182 engages the seal 184. In an exemplary embodiment, the seal 184 iscomposed of urethane. In an exemplary embodiment, the extension of theseal 184 within the channels 176, 178 a, and 178 b facilitates insecuring the seal 184 to the valve body 168. In an exemplary embodiment,the combination of the O-ring 182, and the extension of the seal 184within the channels 176, 178 a, and 178 b, facilitates in securing theseal 184 to the valve body 168. The seal 184 defines an outsidecircumferentially-extending exterior 186. An annular channel 188 isformed in the exterior 186. The seal 184 further includes an annularbulbous protrusion 190. The channel 188 is positioned vertically betweena top surface 192 of the valve body 168 and the bulbous protrusion 190.In an exemplary embodiment, the bulbous protrusion 190 is adjacent thechannel 188. In an exemplary embodiment, as shown in FIG. 10, thechannel 188 is positioned vertically between the top surface 192 and thebulbous protrusion 190, and the bulbous protrusion 190 is adjacent thechannel 188. A tapered and circumferentially-extending surface 194extends angularly downward from the bulbous protrusion 190, theextension of the surface 194 ending at, or proximate, the valve body168.

In several exemplary embodiments, the seal 184 is a unitary structureand thus the surface 186, the channel 188, the bulbous protrusion 190,and the surface 194, as well as the respective portions of the seal 184extending within the channels 176, 178 a, and 178 b, are integrallyformed.

In several exemplary embodiments, the seal 184 is a unitary structure ofurethane, and thus the surface 186, the channel 188, the bulbousprotrusion 190, and the surface 194, as well as the respective portionsof the seal 184 extending within the channels 176, 178 a, and 178 b, areintegrally formed using urethane.

As shown in FIGS. 10 and 11, the valve body 168 includes an annularchannel 196, about which the top surface 192 circumferentially extends.An annular ridge 198 is formed in the valve body 168 adjacent thechannel 196, and is radially positioned between the channel 196 and thetop surface 192. An axially-facing surface 200 is defined by the channel196, and a protrusion 202 extends axially upwards from the surface 200and out of the channel 196. The lower end portion of the spring 108 (notshown in FIGS. 10 and 11) is engaged with the surface 200. Theprotrusion 202 extends within the lower end portion of the spring 108.

The valve body 168 defines a frusto-conical surface 204, which extendsangularly upwardly from the base 164. A frusto-conical surface 206 isalso defined by the valve body 168, the frusto-conical surface 206extending angularly between the frusto-conical surface 204 of the valvebody 168 and the tapered and circumferentially-extending surface 194 ofthe seal 184.

The plurality of circumferentially-spaced legs 106 extend angularlydownward from the base 164, and slidably engage the inside surface 85 ofthe seat body 80 of the valve seat 152. In several exemplaryembodiments, the plurality of legs 106 may include two, three, four,five, or greater than five, legs 106.

An angle 208 is defined by the frusto-conical surface 206. The angle 208may be measured from a valve member axis 210. The valve member axis 210is aligned, or coaxial, with valve seat axis 84 when the inlet valve 150is disposed in the fluid passage 38 of the fluid end block 18. Thus, theaxes 210, 84, and 42 are aligned, or coaxial, with each other when theinlet valve 150 is disposed in the first fluid passage 38 of the fluidend block 18.

In an exemplary embodiment, the angle 208, as measured from the valvemember axis 210, is substantially equal to the angle 162 defined by thetapered surface 96, as measured from the valve seat axis 84. In anexemplary embodiment, the angle 208 is 50 degrees from the valve memberaxis 210, and the angle 162 is 50 degrees from the valve seat axis 84.

An angle 214 is defined by the frusto-conical surface 204. As measuredfrom the valve member axis 210, the angle 214 is greater than the angle208.

An angle 216 (shown most clearly in FIG. 11) is defined by the taperedsurface 194 of the seal 184. The angle 216 may be measured from thevalve member axis 210. In an exemplary embodiment, the angle 216 issubstantially equal to the angle 208 when measured from the valve memberaxis 210. In an exemplary embodiment, the angle 216 is greater than theangle 208 when measured from the valve member axis 210. In an exemplaryembodiment, the angle 216 is substantially equal to, or greater than,the angle 208 when measured from the valve member axis 210. In anexemplary embodiment, the angle 216 is less than, substantially equalto, or greater than, the angle 208 when measured from the valve memberaxis 210.

In an exemplary embodiment, the valve member 154 is composed of AISI8620 alloy steel material. In an exemplary embodiment, the valve seat152 is composed of AISI 8620 alloy steel material. In an exemplaryembodiment, the valve seat 152 is composed of AISI 52080 alloy steelmaterial.

The valve member 154 is movable, relative to the valve seat 152 and thefluid end block 18, between a closed position (not shown but describedbelow) and an open position (shown in FIG. 10 and described below).

In an exemplary embodiment, as shown in FIG. 11, the seal 184 includes acircumferentially-extending upper tab 218, which extends upwardly fromthe channel 188 and encircles the top surface 192 of the valve body 168.A top surface 220 is defined by the tab 218. As shown in FIG. 11, thetop surface 220 of the seal 184 and the top surface 192 of the valvebody 168 are substantially flush. An annular channel 222 is formed inthe tab 218 at the exterior 186 of the seal 184. In several exemplaryembodiments, as shown in FIG. 11, the channels 176, 178 a, and 178 b maybe omitted from the valve body 168.

In an exemplary embodiment, the seal 184 is molded in place in the valvebody 168. In an exemplary embodiment, the seal 184 is preformed and thenattached to the valve body 168. In several exemplary embodiments, theseal 184 is composed of one or more materials such as, for example, adeformable thermoplastic material, a urethane material, afiber-reinforced material, carbon, glass, cotton, wire fibers, cloth,and/or any combination thereof. In an exemplary embodiment, the seal 184is composed of a cloth which is disposed in a thermoplastic material,and the cloth may include carbon, glass, wire, cotton fibers, and/or anycombination thereof. In several exemplary embodiments, the seal 184 iscomposed of at least a fiber-reinforced material, which prevents, or atleast reduces, delamination. In an exemplary embodiment, the seal 184has a hardness of 95 A durometer or greater, or a hardness of 69 Ddurometer or greater. In several exemplary embodiments, the valve body168 is much harder and/or more rigid than the seal 184.

In an exemplary embodiment, with reference to FIGS. 2, 3, 10, and 11,the inlet valve 54 is omitted from the pump assembly 10 in favor of theinlet valve 150, which is disposed in the fluid passage 38. However, thetapered internal shoulder 43 is omitted from the fluid end block 18, infavor of an axially-facing internal shoulder 224 (shown in FIG. 10),which is defined by the enlarged-diameter portion 38 a of the fluidinlet passage 38 of the fluid end block 18. Alternatively, thisexemplary embodiment may be described as including the tapered internalshoulder 43, but the taper angle of the tapered internal shoulder 43 is90 degrees when measured from the axis 42.

When the inlet valve 150 is disposed in the fluid passage 38, theexternal shoulder 156 of the valve seat 152 is engaged with the internalshoulder 224 of the fluid end block 18. The O-ring 88 (shown in FIG. 3)is disposed in the annular groove 90 and sealingly engages the insidesurface 46 of the fluid end block 18. The outside surface 86 of the body80 of the valve seat 152 of the inlet valve 150 engages the insidesurface 46 of the fluid end block 18. In an exemplary embodiment, atleast the reduced-diameter portion 38 b of the fluid passage 38 istapered such that its inside diameter decreases along the fluid passage38 in an axial direction away from the enlarged-diameter portion 38 a.In an exemplary embodiment, an interference fit is formed between theoutside surface 86 and the inside surface 46, thereby preventing thevalve seat 152 from being dislodged from the fluid passage 38. The lowerportion of the spring 108 engages the surface 200 of the valve body 168,while the upper portion of the spring 108 engages the valve springretainer 72. The spring 108 of the inlet valve 150 is thus compressedbetween the surface 200 and the valve spring retainer 72.

In an exemplary embodiment, with reference to FIGS. 2, 3, 10, and 11,the outlet valve 56 is omitted from the pump assembly 10 in favor of anoutlet valve that is identical to the inlet valve 150, and this outletvalve is disposed in the fluid passage 40. However, the tapered internalshoulder 48 is omitted from the fluid end block 18, in favor of anaxially-facing internal shoulder (not shown but identical to theshoulder 224), which is defined by the enlarged-diameter portion 40 a ofthe fluid outlet passage 40 of the fluid end block 18. Alternatively,this exemplary embodiment may be described as including the taperedinternal shoulder 48, but the taper angle of the tapered internalshoulder 48 is 90 degrees when measured from the axis 42.

The outlet valve, which is identical to the inlet valve 150, is disposedin the fluid passage 40, and engages the fluid end block 18, in a mannerthat is identical to the manner in which the inlet valve 150 is disposedin the fluid passage 38, and engages the fluid end block 18, with oneexception. This one exception involves the spring 108 of the outletvalve that is identical to the inlet valve 150; more particularly, theupper portion of the spring 108 of the outlet valve is compressedagainst the bottom of the plug 64, rather than being compressed againsta component that corresponds to the valve spring retainer 72, againstwhich the upper portion of the spring 108 of the inlet valve 150 iscompressed.

In operation, in an exemplary embodiment, with continuing reference toFIGS. 1-11, the plunger 32 reciprocates within the bore 34,reciprocating in and out of the pressure chamber 36. That is, theplunger 32 moves back and forth horizontally, as viewed in FIG. 2, awayfrom and towards the fluid passage axis 42. In an exemplary embodiment,the engine or motor (not shown) drives the crankshaft (not shown)enclosed within the housing 16, thereby causing the plunger 32 toreciprocate within the bore 34 and thus in and out of the pressurechamber 36.

As the plunger 32 reciprocates out of the pressure chamber 36, the inletvalve 150 is opened. More particularly, as the plunger 32 moves awayfrom the fluid passage axis 42, the pressure inside the pressure chamber36 decreases, creating a differential pressure across the inlet valve150 and causing the valve member 154 to move upward, as viewed in FIGS.2, 3, and 10, relative to the valve seat 152 and the fluid end block 18.As a result of the upward movement of the valve member 154, the spring108 is compressed between the valve body 168 and the valve springretainer 72, the seal 184 disengages from the tapered surface 96, andthe inlet valve 150 is thus placed in its open position. Fluid in thefluid inlet passage 22 flows along the fluid passage axis 42 and throughthe fluid passage 38 and the inlet valve 150, being drawn into thepressure chamber 36. To flow through the inlet valve 150, the fluidflows through the bore 83 of the valve seat 152 and along the valve seataxis 84. During the fluid flow through the inlet valve 150 and into thepressure chamber 36, the outlet valve (which is identical to the inletvalve 150 as described above) is in its closed position, with the seal184 of the valve member 154 of the outlet valve engaging the taperedsurface 96 of the valve seat 152 of the outlet valve. Fluid continues tobe drawn into the pressure chamber 36 until the plunger 32 is at the endof its stroke away from the fluid passage axis 42. At this point, thedifferential pressure across the inlet valve 150 is such that the spring108 of the inlet valve 54 is not further compressed, or begins todecompress and extend, forcing the valve member 154 of the inlet valve150 to move downward, as viewed in FIGS. 2, 3, and 10, relative to thevalve seat 152 and the fluid end block 18. As a result, the inlet valve150 is placed in, or begins to be placed in, its closed position, withthe seal 184 sealingly engaging, or at least moving towards, the taperedsurface 96.

As the plunger 32 moves into the pressure chamber 36 and thus towardsthe fluid passage axis 42, the pressure within the pressure chamber 36begins to increase. The pressure within the pressure chamber 36continues to increase until the differential pressure across the outletvalve (which is identical to the inlet valve 150) exceeds apredetermined set point, at which point the outlet valve opens andpermits fluid to flow out of the pressure chamber 36, along the fluidpassage axis 42 and through the fluid passage 40 and the outlet valve,and into the fluid outlet passage 24. As the plunger 32 reaches the endof its stroke towards the fluid passage axis 42 (i.e., its dischargestroke), the inlet valve 150 is in, or is placed in, its closedposition, with the seal 184 sealingly engaging the tapered surface 96.

The foregoing is repeated, with the reciprocating pump assembly 10pressurizing the fluid as the fluid flows from the fluid inlet passage22 and to the fluid outlet passage 24 via the pressure chamber 36. In anexemplary embodiment, the pump assembly 10 is a single-actingreciprocating pump, with fluid being pumped across only one side of theplunger 32.

In an exemplary embodiment, during the above-described operation of thereciprocating pump assembly 10 with the inlet valve 150 and the outletvalve that is identical to the inlet valve 150, the shape of the seal184 provides improved contact pressure against the tapered surface 96,thereby providing a better seal in the closed position. In particular,in an exemplary embodiment, the surface 194 provides improved contactpressure against the tapered surface 96. In an exemplary embodiment, thecombination of the surface 194 and the bulbous protrusion 190 providesimproved contact pressure against the tapered surface 96.

In an exemplary embodiment, when the inlet valve 150 is in the closedposition, at least the surface 194 seals against the tapered surface 96,and at least the surface 206 of the valve body 168 contacts the taperedsurface 96 of the valve seat 152. In several exemplary embodiments, thecontact between the surfaces 206 and 96 is steel-to-steel contact, whichmay be susceptible to damage and wear. However, the combination of thefrusto-conical surfaces 204 and 206 greatly reduces the maximum steelcontact pressure between the surfaces 206 and 96, greatly reducingdamage and wear. In several exemplary embodiments, specifying the angle162 at 50 degrees from the axis 84 (or 40 degrees from horizontal), andthe angle 208 at 50 degrees from the axis 210 (or 40 degrees fromhorizontal), reduces the maximum steel contact pressure. In severalexemplary embodiments, the steel/urethane ratio reduces the maximumsteel contact pressure. In several exemplary embodiments, the ratio ofthe contact area of the valve body 168 against the surface 96, to thecontact area of the seal 184 against the surface 96, reduces the maximumsteel contact pressure.

In an exemplary embodiment, when the inlet valve 150 is in the closedposition, the steel-to-steel contact between the surfaces 206 and 96results in maximum stress in the valve body 168 of the valve member 154,and/or in the seat body 80 of the valve seat 152. However, thecombination of the frusto-conical surfaces 204 and 206 greatly reducesthis maximum stress. In several exemplary embodiments, thesteel/urethane ratio reduces the maximum stress. In several exemplaryembodiments, the ratio of the contact area of the valve body 168 againstthe surface 96, to the contact area of the seal 184 against the surface96, reduces the maximum stress.

Comparing the valve body 100 of FIG. 6 with the valve body 168 of FIG.10, the filling in of the valve body 168 with material, to define thesurfaces 204 and 206, increases strength and reduces turbulence. Inseveral exemplary embodiments, specifying the angle 162 at 50 degreesfrom the axis 84 (or 40 degrees from horizontal), and the angle 208 at50 degrees from the axis 210 (or 40 degrees from horizontal), providesfor better fluid flow and contact area.

In several experimental exemplary embodiments, experimental finiteelement analyses were conducted on an Experimental Baseline Embodimentof an inlet valve and an Experimental Exemplary Embodiment of the inletvalve 150 illustrated in FIG. 10. The Experimental Baseline Embodimentwas similar in design and configuration to the inlet valve 128illustrated in FIG. 6, except that the tapered external shoulder 91 andthus the frusto-conical surface 92 were omitted; instead, theExperimental Baseline Embodiment included an external shoulder identicalto the external shoulder 156 of the inlet valve 150, and thus includedan axially-facing and circumferentially-extending surface identical tothe surface 158 of the inlet valve 150. During the experimental finiteelement analyses, the Experimental Baseline Embodiment and theExperimental Exemplary Embodiment of the inlet valve 150 were of thesame valve size to work in the same size of fluid end block 18, and weresubject to the same operational parameters (pressure, force loading,etc.).

In an exemplary experimental embodiment, FIG. 12 is a view ofexperimental steel contact pressures experienced by a finite elementmodel of the Experimental Exemplary Embodiment of the inlet valve 150 ofFIG. 10, according to an exemplary experimental embodiment. The maximumsteel contact pressure between the valve body 168 and the seat body 80was found to be in the vicinity of point A in FIG. 12, with a value ofabout 60 ksi. The equivalent Experimental Baseline Embodiment had amaximum steel contact pressure of about 244 ksi. Thus, the inlet valve150 provides at least a 75% reduction in maximum steel contact pressurebetween the valve body 168 and the seat body 80. This was an unexpectedresult. The portion of the surface area of the surface 96 adapted toundergo steel-to-steel contact was about doubled (2× to 2.2×), yet thisdoubling provided a 75% reduction in maximum steel contact pressure,rather than just a 50% reduction as might have been expected. Thus, the75% reduction in maximum contact pressure was an unexpected result.

In an exemplary experimental embodiment, FIG. 13 is a view ofexperimental stresses experienced by a finite element model of theExemplary Experimental Embodiment of the inlet valve 150 of FIG. 10,according to an exemplary experimental embodiment. The maximum stressdue to the contact between the valve body 168 and the seat body 80 wasfound to be in the vicinity of point B in FIG. 13, with a value of about68 ksi. The equivalent Experimental Baseline Embodiment had a maximumstress of about 130 ksi. Thus, the inlet valve 150 provides at least a48% reduction in maximum stress.

In an exemplary experimental embodiment, FIG. 14 is a view ofexperimental urethane contact pressures experienced by a finite elementmodel of the Exemplary Experimental Embodiment of the inlet valve 150 ofFIG. 10, according to an exemplary experimental embodiment. The maximumurethane contact pressure provide by the seal 184 against the surface 96was found to be in the vicinity of point C in FIG. 14, and was 500 psihigher than the maximum urethane contact pressure of the equivalentExperimental Baseline Embodiment.

In an exemplary experimental embodiment, the contact area between theseal 184 and the surface 96 of the Exemplary Experimental Embodiment ofthe inlet valve 150 was 6.388 in², and the contact area between thesurface 206 and the surface 96 of the Exemplary Experimental Embodimentwas 6.438 in²; and the contact area between the seal 184 and the surface96 of the Experimental Baseline Embodiment was 7.166 in², and thecontact area between the surface 206 and the surface 96 of theExperimental Baseline Embodiment was 3.176 in².

In an exemplary embodiment, the contact area between the seal 184 andthe surface 96 of the inlet valve 150 is 6.388 in² (e.g., urethanecontact), and the contact area between the surface 206 and the surface96 of the inlet valve 150 is 6.438 in² (e.g., steel contact). In anexemplary embodiment, the steel/urethane contact ratio of the inletvalve 150 is 6.438/6.388, or about 1. In an exemplary embodiment, thesteel/urethane contact ratio of the inlet valve 150 is 6.82/6.22, orabout 1.1. In an exemplary embodiment, the steel/urethane contact ratioranges from about 0.9 to about 1.2. In an exemplary embodiment, theratio of the contact area between the surface 206 and the surface 96 ofthe inlet valve 150, to the contact area between the seal 184 and thesurface 96 of the inlet valve 150, is about 1, about 1.1, or ranges fromabout 0.9 to about 1.2.

In an exemplary embodiment, as illustrated in FIGS. 15-18, a valvemember is generally referred to by the reference numeral 230 andincludes a central disk-shaped central base 232, which defines anoutside circumferentially-extending convex surface 234. A valve body 236extends axially upwards from the base 232, along a valve member axis237. In an exemplary embodiment, the valve member axis 237 is aligned,or coaxial, with the valve seat axis 84 shown in FIG. 10. Thus, inseveral exemplary embodiments, the valve member axis 237 is aligned, orcoaxial, with the fluid passage axis 42 shown in FIG. 10. The valve body236 also extends radially outward from the valve member axis 237.

As shown in FIGS. 17 and 18, an outside annular cavity 240 is formed inthe valve body 236 and defines a concave surface 241. A generallytapered and circumferentially-extending surface 242, which extendsangularly downward to the concave surface 241, is defined by the outsideannular cavity 240. A generally tapered and circumferentially-extendingsurface 244, which extends angularly upward to the concave surface 241,is also defined by the outside annular cavity 240.

As shown in FIGS. 15 and 17, the valve body 236 includes an annularchannel 246, about which a top surface 248 circumferentially extends. Anannular ridge 250 is adjacent the channel 246, and is radiallypositioned between the channel 246 and the top surface 248. Anaxially-facing surface 252 is defined by the channel 246, and aprotrusion 254 extends axially upwards from the surface 252 and out ofthe channel 246. In an exemplary embodiment, the surface 252 is engagedwith a lower end portion of a spring, such as the spring 108 of FIG. 3.In an exemplary embodiment, the protrusion 254 extends within a lowerend portion of a spring, such as the spring 108 of FIG. 3.

A seal 256 extends within the outside annular cavity 240, and is adaptedto sealingly engage a tapered surface of a valve seat, such as thetapered surface 96 of the valve seat 152 of FIG. 10. In an exemplaryembodiment, the seal 256 is composed of urethane. In an exemplaryembodiment, the extension of the seal 256 within the cavity 240facilitates in securing the seal 256 to the valve body 236. The seal 256defines an outside circumferentially-extending exterior 258. An annularchannel 260 is formed in the exterior 258. The seal further includes anannular bulbous protrusion 262. The channel 260 is positioned verticallybetween the top surface 248 of the valve body 236 and the bulbousprotrusion 262. In an exemplary embodiment, the bulbous protrusion 262is positioned adjacent the channel 260. In an exemplary embodiment, thechannel 260 is positioned vertically between the top surface 248 and thebulbous protrusion 262, and the bulbous protrusion 262 is adjacent thechannel 260.

The seal 256 also includes a circumferentially-extending upper tab 264,which extends upwardly from the channel 260 and encircles the topsurface 248 of the valve body 236. A top surface 266 is defined by thetab 264. As shown in FIG. 17, the top surface 266 of the seal 256 andthe top surface 248 of the valve body 236 are substantially flush. Anannular channel 268 is formed in the tab 264 at the exterior 258 of theseal 256. In an exemplary embodiment, the annular channel 268 ispositioned vertically between the top surface 266 of the seal 256 andthe annular channel 260. In an exemplary embodiment, the annular channel268 is positioned vertically between the top surface 266 of the seal 256and the bulbous protrusion 262.

As shown most clearly in FIGS. 17 and 18, frusto-conical surfaces 270and 272 are defined by the seal 256. In several exemplary embodiments,the frusto-conical surfaces 270 and 272 may be characterized as firstand second tapered and circumferentially-extending surfaces,respectively. The frusto-conical surface 270 extends angularly downwardfrom the bulbous protrusion 262, the extension of the frusto-conicalsurface 270 ending at, or proximate, the frusto-conical surface 272. Thefrusto-conical surface 272 extends angularly downward from thefrusto-conical surface 270 ending at, or proximate, the valve body 236.An annular contact portion 274 is defined at the intersection betweenthe frusto-conical surface 270 and the frusto-conical surface 272. Thecontact portion 274 includes at least a portion of the frusto-conicalsurface 270. In an exemplary embodiment, the contact portion 274includes at least respective portions of the frusto-conical surfaces 270and 272.

In several exemplary embodiments, the seal 256 is a unitary structureand thus the exterior 258, the upper tab 264, the channel 268, thechannel 260, the bulbous protrusion 262, and the surface 266, includingthe frusto-conical surfaces 270 and 272, as well as the respectiveportions of the seal 256 extending within the channel 240, areintegrally formed.

In several exemplary embodiments, the seal 256 is a unitary structure ofurethane, and thus the exterior 258, the upper tab 264, the channel 268,the channel 260, the bulbous protrusion 262, and the surface 266,including the frusto-conical surfaces 270 and 272, as well as therespective portions of the seal 256 extending within channel 240, areintegrally formed.

The valve body 236 defines a frusto-conical surface 276, which extendsangularly upwardly from the base 232. A frusto-conical surface 278 isalso defined by the valve body 236, the frusto-conical surface 278extending angularly between the frusto-conical surface 276 of the valvebody 236 and the frusto-conical surface 272 of the seal 256.

A plurality of circumferentially-spaced legs 280 extend angularlydownward from the base 232, and are adapted to slidably engage an insidesurface of a seat body of a valve seat, such as the inside surface 85 ofthe seat body 80 of the valve seat 152 of FIG. 10. In several exemplaryembodiments, the plurality of legs 280 may include two, three, four,five, or greater than five, legs 280.

An angle 282 is defined by the frusto-conical surface 278. The angle 282may be measured from the valve member axis 237. In an exemplaryembodiment, the angle 282, as measured from the valve member axis 237,is substantially equal to the angle 162 defined by the tapered surface96, as measured from the valve seat axis 84, as shown in FIG. 10. In anexemplary embodiment, the angle 282 is about 50 degrees from the valvemember axis 237, and the angle 162 is about 50 degrees from the valveseat axis 84. In an exemplary embodiment, the angle 282 is substantiallyequal to, or greater than (e.g., 51 degrees, 52 degrees, 53 degrees, 54degrees, 55 degrees, or more), the angle 162 of FIG. 10 when measuredfrom the valve member axis 237. In an exemplary embodiment, the angle282 is less than (e.g., 49 degrees, 48 degrees, 47 degrees, 46 degrees,45 degrees, or less), substantially equal to, or greater than, the angle162 when measured from the valve member axis 237.

An angle 286 is defined by the frusto-conical surface 276. As measuredfrom the valve member axis 237, the angle 286 is greater than the angle282. In an exemplary embodiment, the angle 286 is about 70 degrees whenmeasured from the valve member axis 237. In an exemplary embodiment, theangle 286 ranges from about 60 degrees to about 85 degrees when measuredfrom the valve member axis 237. In an exemplary embodiment the angle 286ranges from about 65 degrees to about 80 degrees.

An angle 288 (shown most clearly in FIG. 18) is defined by thefrusto-conical surface 272 of the seal 256. The angle 288 may bemeasured from the valve member axis 237. In an exemplary embodiment, theangle 288 is greater than the angle 282 when measured from the valvemember axis 237. In an exemplary embodiment, the angle 282 is about 62.5degrees. The angles 282 and 288 define an angle 290 therebetween. In anexemplary embodiment, the angle 290 is about 12.5 degrees. In anexemplary embodiment, the angle 290 ranges from about 0 degrees to about25 degrees. In an exemplary embodiment, the angle 290 ranges from about5 degrees to about 20 degrees. In an exemplary embodiment, the angle 290ranges from about 10 degrees to about 15 degrees.

An angle 292 is defined by the frusto-conical surface 270 of the seal256. The angle 292 may be measured from the valve member axis 237. In anexemplary embodiment, the angle 292 is substantially equal to the angle282 when measured from the valve member axis 237. In an exemplaryembodiment, the angle 292 is less than the angle 288 when measured fromthe valve member axis 237. As a result, as indicated by the referencenumeral D₁, the contact portion 274 is offset a distance D₁ from thefrusto-conical surface 278 in a direction perpendicular to thefrusto-conical surface 278. In an exemplary embodiment, the offsetdistance D₁ is about 0.06 inches. In an exemplary embodiment, the offsetdistance D₁ ranges from about 0.04 inches to about 0.08 inches. In anexemplary embodiment, the offset distance D₁ ranges from greater than 0inches to about 0.1 inches. In an exemplary embodiment, thefrusto-conical surfaces 270 and 278 are spaced in parallel relation andthe parallel spacing therebetween defines the offset distance D.

In an exemplary embodiment, the valve member 230 is adapted and sized tobe used with an SPM SP4 full open well service seat.

In an exemplary embodiment, the valve member 230 is composed of AISI8620 alloy steel material.

In an exemplary embodiment, the valve member 230 is movable, relative toa valve seat, such as the valve seat 152 of FIG. 10, and a fluid endblock, such as the fluid end block 18 of FIG. 10, between a closedposition (not shown but described below) and an open position (not shownbut described below). In such embodiments, the valve seat 152 is offsetfrom the valve member 230 such that the tapered surface 96 is offset adistance (not shown) from the valve member 230.

In an exemplary embodiment, the seal 256 is molded in place in the valvebody 236. In an exemplary embodiment, the seal 256 is preformed and thenattached to the valve body 236. In an exemplary embodiment, the seal 256is bonded to the valve body 236. As noted above, in an exemplaryembodiment, the seal 256 is composed of urethane. In several exemplaryembodiments, the seal 256 is composed of one or more materials such as,for example, a deformable thermoplastic material, a urethane material, afiber-reinforced material, carbon, glass, cotton, wire fibers, cloth,and/or any combination thereof. In an exemplary embodiment, the seal 256is composed of a cloth which is disposed in a thermoplastic material,and the cloth may include carbon, glass, wire, cotton fibers, and/or anycombination thereof. In several exemplary embodiments, the seal 256 iscomposed of at least a fiber-reinforced material, which prevents, or atleast reduces, delamination. In an exemplary embodiment, the seal 256has a hardness of 95 A durometer or greater, or a hardness of 69 Ddurometer or greater. In several exemplary embodiments, the valve body236 is much harder and/or more rigid than the seal 256.

In an exemplary embodiment, the valve member 154 of FIGS. 10 and 11 isomitted in favor of the valve member 230. In operation, in suchembodiments, with continuing reference to FIGS. 1-18, the plunger 32reciprocates within the bore 34, reciprocating in and out of thepressure chamber 36. That is, the plunger 32 moves back and forthhorizontally, as viewed in FIG. 2, away from and towards the fluidpassage axis 42. In an exemplary embodiment, the engine or motor (notshown) drives the crankshaft (not shown) enclosed within the housing 16,thereby causing the plunger 32 to reciprocate within the bore 34 andthus in and out of the pressure chamber 36.

As the plunger 32 reciprocates out of the pressure chamber 36, the inletvalve 150 is opened. More particularly, as the plunger 32 moves awayfrom the fluid passage axis 42, the pressure inside the pressure chamber36 decreases, creating a differential pressure across the inlet valve150 and causing the valve member 230 to move upward, relative to thevalve seat 152 and the fluid end block 18. As a result of the upwardmovement of the valve member 230, the spring 108 is compressed betweenthe valve body 236 and the valve spring retainer 72, the seal 256disengages from the tapered surface 96, and the inlet valve 150 is thusplaced in its open position. Fluid in the fluid inlet passage 22 flowsalong the fluid passage axis 42 and through the fluid passage 38 and theinlet valve 150, being drawn into the pressure chamber 36. To flowthrough the inlet valve 150, the fluid flows through the bore 83 of thevalve seat 152 and along the valve seat axis 84. During the fluid flowthrough the inlet valve 150 and into the pressure chamber 36, the outletvalve 56 (which is identical to the inlet valve 150 as described above)is in its closed position, with the seal 256 of the valve member 230 ofthe outlet valve 56 engaging the tapered surface 96 of the valve seat152 of the outlet valve 56. Fluid continues to be drawn into thepressure chamber 36 until the plunger 32 is at the end of its strokeaway from the fluid passage axis 42. At this point, the differentialpressure across the inlet valve 150 is such that the spring 108 of theinlet valve 150 is not further compressed, or begins to decompress andextend, forcing the valve member 230 of the inlet valve 150 to movedownward relative to the valve seat 152 and the fluid end block 18. As aresult, the inlet valve 150 is placed in, or begins to be placed in, itsclosed position, with the seal 256 sealingly engaging, or at leastmoving towards, the tapered surface 96.

As the plunger 32 moves into the pressure chamber 36 and thus towardsthe fluid passage axis 42, the pressure within the pressure chamber 36begins to increase. The pressure within the pressure chamber 36continues to increase until the differential pressure across the outletvalve 56 exceeds a predetermined set point, at which point the outletvalve 56 opens and permits fluid to flow out of the pressure chamber 36,along the fluid passage axis 42 and through the fluid passage 40 and theoutlet valve 56, and into the fluid outlet passage 24. As the plunger 32reaches the end of its stroke towards the fluid passage axis 42 (i.e.,its discharge stroke), the inlet valve 54 is in, or is placed in, itsclosed position, with the seal 256 sealingly engaging the taperedsurface 96.

In an exemplary embodiment, the configuration of the seal 256 providesimproved sealing engagement with the tapered surface 96, therebyproviding an improved seal when the inlet valve 150 and/or the identicaloutlet valve 56 are in respective closed positions. In particular, in anexemplary embodiment, the offset distance D₁ of the contact portion 274ensures that at least the annular contact portion 274 sealingly engagesthe tapered surface 96 as the valve member 230 moves downward relativeto the valve seat 152. More particularly, the offset distance D₁ ensuresthat, as the valve member 230 moves downward, the annular contactportion 274 will contact the tapered surface 96 before thefrusto-conical surface 278, ensuring the sealing engagement between theseal 256 and the surface 96. In an exemplary embodiment, the offsetdistance D₁ of the contact portion 274 ensures that at least the contactportion 274 sealingly engages the tapered surface 96 as the valve member230 moves downward relative to the valve seat 152. In an exemplaryembodiment, as the valve member 230 moves downward relative to the valveseat 152, the contact portion 274 engages the tapered surface 96 beforeother surfaces of the valve member 230. For example, the contact portion274 engages the surface 96 before the frusto-conical surface 278, beforethe frusto-conical surface 272, and/or before the frusto-conical surface270 engages the tapered surface 96. In an exemplary embodiment, theangle 290 ensures that at least the contact portion 274 sealinglyengages the tapered surface 96 as the valve member 230 moves downwardrelative to the valve seat 152. In an exemplary embodiment, thedifference between the angle 292 and the angle 288 and the differencebetween the angle 282 and the angle 288 ensure that at least the contactportion 274 sealingly engages the tapered surface 96 as the valve member230 moves downward relative to the valve seat 152.

In an exemplary embodiment, as the valve member 230 moves downwardrelative to the valve seat 152, initially, the contact portion 274sealingly engages the tapered surface 96; as noted above, at least aportion of frusto-conical surface 270, or at least respective portionsof the frusto-conical surfaces 270 and 272 sealingly engage the taperedsurface 96. As the valve member 230 continues to move downward relativeto the valve seat 152, the seal 256 deforms radially from the contactportion 274. As a result, in an exemplary embodiment, at leastrespective additional portions of the frusto-conical surfaces 270 and272 also sealingly engage the surface 96.

The foregoing is repeated, with the reciprocating pump assembly 10pressurizing the fluid as the fluid flows from the fluid inlet passage22 and to the fluid outlet passage 24 via the pressure chamber 36. In anexemplary embodiment, the pump assembly 10 is a single-actingreciprocating pump, with fluid being pumped across only one side of theplunger 32.

In several exemplary embodiments, the valve member 78 of FIG. 3 isomitted in favor of the valve member 230. In several exemplaryembodiments, the valve member 230 is used with any of the valve seats,including, but not limited to, the valve seat 76 and the valve seat 128.In several exemplary embodiments, the valve member 230 is used withother valve seats having configurations different from that of the valveseat 76 and/or the valve seat 128. In several exemplary embodiments, thevalve member 230 is used with any of the inlet and outlet valves,including the inlet valve 54, the inlet valve 128, the outlet valve 56,and/or other differently configured inlet and outlet valves.

In an exemplary embodiment, as illustrated in FIGS. 19-21, a valvemember is generally referred to by the reference numeral 294 andincludes several parts that are identical to corresponding parts of thevalve member 230, which identical parts are given the same referencenumerals. As shown in FIGS. 19 and 21, the valve member 294 includes arupture disc assembly 296.

As shown most clearly in FIG. 21, a counterbore 298 is formed in thevalve body 236, and is generally coaxial with the valve member axis 237.The counterbore 298 extends all the way through the valve body 236. Thecounterbore 298 includes an enlarged-diameter portion 298 a and areduced-diameter portion 298 b. The reduced-diameter portion 298 bdefines a fluid passage 299 extending axially through the valve body236. The counterbore 298 defines an internal shoulder 300.

The rupture disc assembly 296 is disposed in the enlarged-diameterportion 298 a of the counterbore 298. The rupture disc assembly 296includes a rupture disc 301, which includes an annular mounting portion302 and a domed rupture portion 304 about which the mounting portion 302circumferentially extends. The mounting portion 302 is disposed in theenlarged-diameter portion 298 a of the counterbore 298 and engages theinternal shoulder 300. The mounting portion 302 includes an annularchannel 306 formed in an end portion thereof that engages the internalshoulder 300. One or more annular seals 308 extend within the annularchannel 306 and sealingly engage at least the mounting portion 302 andthe internal shoulder 300.

In several exemplary embodiments, any of the valve members 78, 154, or230 are omitted in favor of the valve member 294. In several exemplaryembodiments, the valve member 294 is used in an inlet valve, such as theinlet valve 150 of FIGS. 10 and 11. In several exemplary embodiments,operation of the pump assembly 10 with the valve member 294 issubstantially identical to the operation of the pump assembly 10 withthe valve member 230, as discussed above with regard to FIGS. 15-18,except for the added operation of the rupture disc assembly 296. Moreparticularly, in operation, with reference to FIGS. 1-21, as the plunger32 moves into the pressure chamber 36, the inlet valve 150 is in itsclosed position and a fluid pressure is exerted in at least an axialdirection generally downwards along the fluid passage axis 42 on therupture disc 301 of the rupture disc assembly 296. The sealingengagement between the one or more annular seals 308 and at least themounting portion 302 and the internal shoulder 300 prevents, or at leastresists, the fluid from flowing from the pressure chamber 36, around therupture disc 301, and thus back into the fluid inlet passage 22. Duringthe operation of the pump assembly 10, if the fluid pressure within thepressure chamber 36 reaches or exceeds an acceptable predeterminedvalue, causing a predetermined pressure differential across the rupturedisc 301, the rupture portion 304 of the rupture disc 301 ruptures. As aresult, the fluid passage 299 is in fluid communication with thepressure chamber 36 via the fluid inlet passage 38, and the rupture discassembly 296 permits fluid to flow from the pressure chamber 36, throughthe fluid inlet passage 38, through the mounting portion 302 and thusback into at least the fluid inlet passage 22 and out of the pumpassembly 10. This fluid flow reduces or relieves the pressure within thepump assembly 10. During operation, in several exemplary embodiments,after the rupture disc 301 ruptures, the diameter of the rupture portion304 is less than the reduced-diameter portion 298 a of the counterbore298 thus increasing the likelihood that shrapnel from the rupturedrupture disc 301 will flow downward and out of the counterbore 298without creating a pressure spike.

In several exemplary embodiments, the valve member 294 is used in anoutlet valve, such as the outlet valve 56 or any other outlet valve. Insuch embodiments, the operation of the pump assembly 10 with the valvemember 294 is substantially identical to the operation of the pumpassembly 10 with the valve member 230, as discussed above with regard toFIGS. 15-18, except for the operation of the rupture disc assembly 296.In operation, with reference to FIGS. 1-21, fluid in the pressurechamber 36 flows along the fluid passage axis 42 and through the fluidpassage 40 and the outlet valve 56, and into the fluid outlet passages40 and 24. A fluid pressure is exerted on the rupture disc 301 of therupture disc assembly 296 in at least an axial direction generallydownwards from the fluid outlet passage 40 and/or the fluid outletpassage 24 along the fluid passage axis 42. The sealing engagementbetween the one or more annular seals 308 and at least the mountingportion 302 and the internal shoulder 300, prevents, or at leastresists, the fluid from flowing around the rupture disc 300, and thusinto the fluid passage 299 and back into at least the pressure chamber36. In an exemplary embodiment, the outlet valve 56 is in its closedposition and thus the sealing engagement of the seal 256 and the surface96 also prevents, or at least resists, the fluid from flowing around theseal 256 and back into at least the pressure chamber 36. If the fluidpressure exerted on the rupture disc 301 reaches or exceeds apredetermined pressure value, causing a predetermined pressuredifferential across the rupture disc 301, the rupture portion 304 of therupture disc 301 ruptures. As a result, the fluid passage 299 is influid communication with the fluid outlet passage 40, and the rupturedisc assembly 296 permits fluid to flow from the fluid outlet passage 40and/or the fluid outlet passage 24, through the rupture disc assembly296 and thus back into at least the pressure chamber 36. This fluid flowreduces or relieves the pressure within the pump assembly 10. Duringoperation, in several exemplary embodiments, after the rupture disc 301ruptures, the diameter of the rupture portion 304 is less than thereduced-diameter portion 298 a of the counterbore 298 thus increasingthe likelihood that shrapnel from the ruptured rupture disc 301 willflow downward and out of the counterbore 298 without creating a pressurespike.

As a result, the rupture disc assembly 296, whether in use in an inletvalve or an outlet valve, such as inlet valve 150 and/or outlet valve56, or any other inlet and/or outlet valve, operates to relieve pressurewithin the pump assembly 10, preventing a further increase in pressureso as to prevent or otherwise substantially reduce the likelihood ofdamage to the pump assembly 10, one or more other components of the pumpassembly, and/or any system(s) and/or component(s) in fluidcommunication therewith.

In an exemplary embodiment, as illustrated in FIGS. 22-25, a valvemember is generally referred to by the reference numeral 310 andincludes several parts that are identical to corresponding parts of thevalve member 230, which identical parts are given the same referencenumerals. In several exemplary embodiments, the components of the valvemember 310 are sized such that the valve member 310 is sized and adaptedfor use in larger inlet valves and outlet valves and/or larger fluidpassages. For example, in several exemplary embodiments, the dimensionsof parts of the valve member 310 are greater than the dimensions of thecorresponding parts of the valve member 230. In an exemplary embodiment,the respective radii of the channels 268 and 260 are increased. In anexemplary embodiment, other dimensions are adjusted such as, forexample, the height of the protrusion 254, the diameter of the seal 256,and the diameter of the valve body 236. In several exemplaryembodiments, the height of the valve member 310 is greater than theheight of the valve member 230.

The valve member 310 includes a plurality of circumferentially-spacedlegs 312 extending from the base 232 and away from the valve body 236.In an exemplary embodiment, the legs 312 are larger than the legs 280 ofFIGS. 15-21. For example, the legs 312 may be longer in length, thickerin width, and/or greater in diameter than the legs 280. In an exemplaryembodiment, the legs 312 are adapted to slidably engage an insidesurface of a larger seat body than, for example, the seat body 80 ofFIG. 10. In an exemplary embodiment, the legs 312 are sized to slidablyengage a seat body having an inner diameter of about 3.13 inches. In anexemplary embodiment, the legs 312 are sized to slidably engage a seatbody having an inner diameter ranging in size from about 3 inches toabout 4 inches. In an exemplary embodiment, the legs 312 are sized toslidably engage a seat body having an inner diameter ranging in sizefrom about 3 inches to about 5 inches. In several exemplary embodiments,the various dimensions, including at least the radii, diameter, length,and/or height of the components of the valve member 310 are adjustedsuch that the valve member 310 is configured for use in valve seats andfluid passages having increased dimensions. For example, in an exemplaryembodiment, the valve member 310 is configured for use with an SPM SP5full open well service seat.

In several exemplary embodiments, the valve body 236 defines a step 313at the intersection of the frusto-conical surface 278 of the valve body236 with the frusto-conical surface 272 of the seal 256. During theoperation of the valve member 310, the step 313 prevents, or at leastreduces, bulging of the seal 156 into the region between thefrusto-conical surface 278 and the tapered surface 96 of the seat body80.

In an exemplary embodiment, the operation of the valve member 310 issubstantially identical to the operation of the valve member 230 andtherefore will not be described in detail.

In an exemplary embodiment, as illustrated in FIGS. 26-28, a valvemember is generally referred to by the reference numeral 314 andincludes several parts that are identical to corresponding parts of thevalve member 310, which identical parts are given the same referencenumerals. The valve member 314 also includes a rupture disc assembly316, which includes several parts that are identical to correspondingparts of the rupture disc assembly 296 of the valve member 294, whichparts are given the same reference numerals, except that thecorresponding parts of the rupture disc assembly 316 are sized inaccordance with the increased dimensions of the valve member 314, asdiscussed above. The rupture disc assembly 316 therefore will not bedescribed in further detail.

In an exemplary embodiment, the operation of the valve member 314 issubstantially identical to the operation of the valve member 294 andtherefore the operation of the valve member 314 will not be described infurther detail.

In an exemplary embodiment, as illustrated in FIG. 29, thefrusto-conical surface 272 of the seal 256 is omitted in favor of a pairof frusto-conical surfaces 272 a and 272 b. The frusto-conical surface272 a extends angularly downward from the frusto-conical surface 270(not visible in FIG. 29). Thus, the annular contact portion 274 isdefined at the intersection between the frusto-conical surface 270 andthe frusto-conical surface 272 a. Similarly, the frusto-conical surface272 b extends angularly downward from the frusto-conical surface 272 aending at, or proximate, the frusto-conical surface 278 of the valvebody 236. An annular inflection portion 318 is defined at theintersection between the frusto-conical surface 272 a and thefrusto-conical surface 272 b.

An angle 320 is defined between the frusto-conical surface 272 a and thefrusto-conical surface 278 of the valve body 236. In an exemplaryembodiment, the angle 320 is about 12.5 degrees. In an exemplaryembodiment, the angle 320 ranges from about 0 degrees to about 25degrees. In an exemplary embodiment, the angle 320 ranges from about 5degrees to about 20 degrees. In an exemplary embodiment, the angle 320ranges from about 10 degrees to about 15 degrees. An angle (not shown)is defined by the frusto-conical surface 272 b of the seal 256. Theangle defined by the frusto-conical surface 272 b may be measured fromthe valve member axis 237. In an exemplary embodiment, the angle definedby the frusto-conical surface 272 b is substantially equal to the angle282 (shown in FIG. 25) defined by the frusto-conical surface 278 whenmeasured from the valve member axis 237.

As indicated by the reference numeral D₂, the frusto-conical surface 272b extends for a distance D₂ beyond the frusto-conical surface 278 of thevalve body 236. Thus, the annular inflection portion 318 is spaced fromthe frusto-conical surface by the distance D₂. In an exemplaryembodiment, the configuration of the seal 256 (i.e., the frusto-conicalsurfaces 272 a and 272 b and the annular inflection portion 318)provides improved manufacturing characteristics.

In an exemplary embodiment, as illustrated in FIG. 30, thecircumferentially-extending upper tab 264 of the seal 256 defines aconcave annular surface 322 positioned above the annular channel 268 (asviewed in FIG. 30) and adjoining the top surface 266. The concaveannular surface 322 extends vertically for a distance D₃ between the topsurface 266 and the annular channel 268. In another exemplaryembodiment, the circumferentially-extending upper tab 218 of the seal184 includes the concave annular surface 322. In an exemplaryembodiment, the configuration of the seal 256 (i.e., the concave annularsurface 322) provides improved manufacturing characteristics.

In several exemplary embodiments, the valves 54, 56, 128, and 150, orthe components thereof, such as the valve seats 76, 129, and 152 and thevalve members 78, 154, 230, 294, 310, and 314 may be configured tooperate in the presence of highly abrasive fluids, such as drilling mud,and at relatively high pressures, such as at pressures of up to about15,000 psi or greater. In several exemplary embodiments, instead of, orin addition to being used in reciprocating pumps, the valves 54, 56,128, and 150, or the components thereof, such as the valve seats 76,129, and 152 and the valve members 78, 154, 230, 294, 310, and 314, maybe used in other types of pumps and fluid systems. Correspondingly,instead of, or in addition to being used in reciprocating pumps, thefluid end block 18 or features thereof may be used in other types ofpumps and fluid systems.

In several exemplary embodiments, while different steps, processes, andprocedures are described as appearing as distinct acts, one or more ofthe steps, one or more of the processes, and/or one or more of theprocedures may also be performed in different orders, simultaneouslyand/or sequentially. In several exemplary embodiments, the steps,processes and/or procedures may be merged into one or more steps,processes and/or procedures.

In several exemplary embodiments, one or more of the operational stepsin each embodiment may be omitted. Moreover, in some instances, somefeatures of the present disclosure may be employed without acorresponding use of the other features. Moreover, one or more of theabove-described embodiments and/or variations may be combined in wholeor in part with any one or more of the other above-described embodimentsand/or variations.

In the foregoing description of certain embodiments, specificterminology has been resorted to for the sake of clarity. However, thedisclosure is not intended to be limited to the specific terms soselected, and it is to be understood that each specific term includesother technical equivalents which operate in a similar manner toaccomplish a similar technical purpose. Terms such as “left” and right”,“front” and “rear”, “above” and “below” and the like are used as wordsof convenience to provide reference points and are not to be construedas limiting terms.

In this specification, the word “comprising” is to be understood in its“open” sense, that is, in the sense of “including”, and thus not limitedto its “closed” sense, that is the sense of “consisting only of”. Acorresponding meaning is to be attributed to the corresponding words“comprise”, “comprised” and “comprises” where they appear.

In addition, the foregoing describes only some embodiments of theinvention(s), and alterations, modifications, additions and/or changescan be made thereto without departing from the scope and spirit of thedisclosed embodiments, the embodiments being illustrative and notrestrictive.

Furthermore, invention(s) have described in connection with what arepresently considered to be the most practical and preferred embodiments,it is to be understood that the invention is not to be limited to thedisclosed embodiments, but on the contrary, is intended to cover variousmodifications and equivalent arrangements included within the spirit andscope of the invention(s). Also, the various embodiments described abovemay be implemented in conjunction with other embodiments, e.g., aspectsof one embodiment may be combined with aspects of another embodiment torealize yet other embodiments. Further, each independent feature orcomponent of any given assembly may constitute an additional embodiment.

What is claimed is:
 1. A valve member for an inlet or outlet valve of areciprocating pump assembly, the valve member comprising: a valve bodydefining a first axis and comprising first and second frusto-conicalsurfaces extending at first and second acute angles, respectively,measured from the first axis in a same angular direction; an outsideannular cavity formed in the valve body, the valve body being a singleunitary structure; and a seal extending within the outside annularcavity, the seal defining a tapered and circumferentially-extendingsurface adapted to sealingly engage a tapered surface of a valve seat ofthe inlet or outlet valve; wherein the second frusto-conical surface ofthe valve body extends angularly between the first frusto-conicalsurface of the valve body and the tapered andcircumferentially-extending surface of the seal.
 2. The valve member ofclaim 1, further comprising: a base from which the valve body extends,wherein the first frusto-conical surface of the valve body extendsangularly between the base and the second frusto-conical surface of thevalve body; and a plurality of circumferentially-spaced legs extendingfrom the base and away from the valve body, wherein the legs are adaptedto slidably engage another surface of the valve seat.
 3. The valvemember of claim 2, wherein the base is a disk-shaped base that defines acircumferentially-extending convex surface.
 4. The valve member of claim1, wherein the first acute angle is greater than the second acute angle.5. The valve member of claim 1, wherein the second acute angle issubstantially equal to a taper angle defined by the tapered surface ofthe valve seat and measured from a second axis of the valve seat;wherein the first and second axes are adapted to be coaxial; and whereinthe second acute angle is about 50 degrees.
 6. The valve member of claim1, wherein the second frusto-conical surface of the valve body defines afirst surface area adapted to contact the tapered surface of the valveseat; wherein the seal defines a second surface area adapted to contactthe tapered surface of the valve seat; and wherein a ratio of the firstsurface area to the second surface area ranges from about 0.9 to about1.2.
 7. The valve member of claim 6, wherein the ratio is about
 1. 8.The valve member of claim 1, wherein the second frusto-conical surfaceof the valve body and at least a portion of the tapered andcircumferentially-extending surface of the seal are spaced in a parallelrelation; and wherein an offset distance is defined by the parallelspacing between the second frusto-conical surface of the valve body andthe at least a portion of the tapered and circumferentially-extendingsurface of the seal.
 9. The valve member of claim 8, wherein the offsetdistance extends in a direction that is perpendicular to at least thesecond frusto-conical surface.
 10. The valve member of claim 8, whereinthe offset distance ranges from greater than zero inches to about 0.1inch.
 11. The valve member of claim 1, wherein the first axis of thevalve body is adapted to be coaxial with a second axis of the valveseat; wherein at least a portion of the tapered andcircumferentially-extending surface of the seal extends at a third acuteangle measured from the first axis in the same angular direction;wherein the second and third acute angles are substantially equal; andwherein each of the second and third acute angles is adapted to besubstantially equal to a taper angle defined by the tapered surface ofthe valve seat and measured from the second axis of the valve seat. 12.A valve member for an inlet or outlet valve of a reciprocating pumpassembly, the valve member comprising: a valve body defining a firstaxis and comprising first and second frusto-conical surfaces extendingat first and second acute angles, respectively, measured from the firstaxis in a same angular direction; an outside annular cavity formed inthe valve body, wherein the outside annular cavity defines first andsecond angularly-extending surfaces; a seal extending within the outsideannular cavity, the seal defining a tapered andcircumferentially-extending surface adapted to sealingly engage atapered surface of a valve seat of the inlet or outlet valve; an annulargroove formed in the valve body at an intersection of the first andsecond angularly-extending surfaces; and an annular element disposed inthe annular groove and engaging the seal, wherein the secondfrusto-conical surface of the valve body extends angularly between thefirst frusto-conical surface of the valve body and the tapered andcircumferentially-extending surface of the seal.
 13. A valve member foran inlet or outlet valve of a reciprocating pump assembly, the valvemember comprising: a valve body defining a first axis; an outsideannular cavity formed in the valve body; and a seal extending within theoutside annular cavity and comprising a first tapered andcircumferentially-extending surface adapted to sealingly engage atapered surface of a valve seat of the inlet or outlet valve, the valveseat defining a second axis with which the first axis of the valve bodyis adapted to be coaxial; a counterbore formed in the valve body alongthe first axis, the counterbore comprising an enlarged-diameter portionand a reduced-diameter portion, the reduced-diameter portion defining afluid passage through the valve body, wherein the counterbore defines aninternal shoulder in the valve body extending radially between theenlarged-diameter portion and the reduced-diameter portion; and arupture disc assembly comprising a rupture disc disposed in theenlarged-diameter portion and engaging the internal shoulder.
 14. Thevalve member of claim 13, wherein the rupture disc comprises: an annularmounting portion disposed in the enlarged-diameter portion so that anend of the annular mounting portion engages the internal shoulder; and adomed rupture portion about which the annular mounting portioncircumferentially extends.
 15. The valve member of claim 14, furthercomprising an annular seal sealingly engaging at least the rupture discand the internal shoulder.
 16. The valve member of claim 15, wherein therupture disc further comprises: an annular channel formed in the end ofthe annular mounting portion engaging the internal shoulder; wherein theannular seal extends within the annular channel and sealingly engages atleast the annular mounting portion and the internal shoulder.
 17. Thevalve member of claim 13, wherein the seal further comprises a secondtapered and circumferentially-extending surface; and wherein the firstand second tapered and circumferentially-extending surfaces extend atfirst and second acute angles, respectively, measured from the firstaxis in a same angular direction.
 18. The valve member of claim 17,wherein the seal further comprises an annular contact portion defined byan intersection between the first and second tapered andcircumferentially-extending surfaces, the annular contact portionincluding at least a portion of the first tapered andcircumferentially-extending surface.
 19. The valve member of claim 17,wherein the valve body comprises a frusto-conical surface; and whereinthe second tapered and circumferentially-extending surface extendsangularly between the first tapered and circumferentially-extendingsurface of the seal and the frusto-conical surface of the valve body.20. The valve member of claim 19, wherein an offset distance is definedbetween the frusto-conical surface of the valve body and at least aportion of the first tapered and circumferentially-extending surface ofthe seal, the offset distance extending in a direction that isperpendicular to at least the frusto-conical surface of the valve body.